Vehicle interior systems having a curved cover glass and display or touch panel and methods for forming the same

ABSTRACT

Embodiments of a vehicle interior system are disclosed. In one or more embodiments, the system includes a base with a curved surface, and a display or touch panel disposed on the curved surface. The display includes a cold-bent glass substrate with a thickness of 1.5 mm or less and a first radius of curvature of 20 mm or greater, and a display module and/or touch panel attached to the glass substrate having a second radius of curvature that is within 10% of the first radius of curvature. Methods for forming such systems are also disclosed.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a continuation and claims the benefit of priorityunder 35 U.S.C. § 120 of U.S. patent application Ser. No. 15/860,850,filed on Jan. 3, 2018, which claims the benefit of priority under 35U.S.C. § 119 of U.S. Provisional Patent Application Ser. No. 62/599,928,filed on Dec. 18, 2017, U.S. Provisional Patent Application Ser. No.62/548,026, filed on Aug. 21, 2017, U.S. Provisional Patent ApplicationSer. No. 62/530,579, filed on Jul. 10, 2017, U.S. Provisional PatentApplication Ser. No. 62/529,782, filed on Jul. 7, 2017, and U.S.Provisional Patent Application Ser. No. 62/441,651, filed Jan. 3, 2017,the contents of which are relied upon and incorporated herein byreference in their entirety.

BACKGROUND

The disclosure relates to vehicle interior systems including cover glassand methods for forming the same, and more particularly to vehicleinterior systems including a display and/or touch panel with a curvedcover glass and methods for forming the same.

Vehicle interiors include curved surfaces and can incorporate displaysand/or touch panel. The materials used to form such curved surfaces aretypically limited to polymers, which do not exhibit the durability andoptical performance of glass. As such, curved glass substrates aredesirable, especially when used as covers for displays and/or touchpanels. Existing methods of forming curved glass substrates, such asthermal forming, have drawbacks including high cost, and opticaldistortion and/or surface marking occurring during curving. Accordingly,there is a need for vehicle interior systems that can incorporate acurved glass substrate in a cost-effective manner and without theproblems typically associated with glass thermal forming processes.

SUMMARY

A first aspect of this disclosure pertains to a vehicle interior system.In one or more embodiments, the vehicle interior system includes a basehaving a curved surface, and a display disposed on the curved surface.As used herein, throughout this disclosure unless otherwise noted, wherea display or display module is used, a touch panel may be substituted orused in addition to the display or display module. The display of one ormore embodiments includes a cold-bent glass substrate having a firstmajor surface, a second major surface opposing the first major surfaceand a minor surface connecting the first major surface and the secondmajor surface, a thickness defined as a distance between the first majorsurface and the second major surface, a width defined as a firstdimension of one of the first or second major surfaces orthogonal to thethickness, and a length defined as a second dimension of one of thefirst or second major surfaces orthogonal to both the thickness and thewidth, and wherein the thickness is 1.5 mm or less, and wherein thesecond major surface comprises a first radius of curvature of 20 mm orgreater, 60 mm or greater, or 250 mm or greater. Unless otherwisespecified, the curvature described herein may be convex, concave, or mayhave a combination of convex and concave portions having the same ordifferent radii from one another.

The display may include a display module attached to the second majorsurface of the curved glass substrate. In one or more embodiments, thedisplay module is flat, curved or flexible. In one or more specificembodiments, the display (or a portion thereof such as a second glasssubstrate) comprises a second radius of curvature that is within 10% ofthe first radius of curvature. In one or more specific embodiments, thefirst radius of curvature may be within 10% of the second radius ofcurvature or the radius of curvature of the curved substrate of the baseon which the vehicle interior system is assembled. The display mayfurther include an adhesive between the glass substrate and the displaymodule. The display module of one or more embodiments includes a secondglass substrate and an optional backlight unit, wherein the second glasssubstrate is disposed adjacent the first major surface and between theoptional backlight unit and the first major surface, and wherein eitherone or both the second glass substrate and the optional backlight unitis curved to exhibit the second radius of curvature. In one or moreembodiments, only the second glass substrate is curved to the secondradius of curvature and the remaining portions of the display module areflat.

A second aspect of this disclosure pertains to a method of forming adisplay. In one or more embodiments, the method includes cold-bending aglass substrate having a first major surface and a second major surfaceopposite the first major surface to a first radius of curvature asmeasured on the second major surface, and laminating a display module tothe first major surface while maintaining the first radius of curvaturein the glass substrate to form the display. In one or more embodiments,the display module (or a portion thereof such as a second glasssubstrate) has a second radius of curvature that is within 10% of thefirst radius of curvature. In one or more embodiments, cold-bending theglass substrate may include applying a vacuum to the second majorsurface to generate the first radius of curvature. The method mayinclude laminating an adhesive to the glass substrate before laminatingthe display module such that the adhesive is disposed between the glasssubstrate and the display module. In one or more embodiments, laminatingthe display module may include laminating a second glass substrate tothe glass substrate; and attaching a backlight unit to the second glasssubstrate. In one or more embodiments, the method includes curvingeither one of or both the second glass substrate and the backlight unitto the second radius of curvature. In one or more embodiments, only thesecond glass substrate is curved to the second radius of curvature andthe remaining portions of the display module are flat (such as thebacklight unit).

Another aspect of the disclosure pertains to a method of cold-bending aglass substrate. The method includes supporting a glass substrate on aframe. In one or more embodiments, the glass substrate has a first majorsurface and a second major surface opposite the first major surface, andthe frame has a curved support surface. The first major surface of theglass substrate may face the curved support surface of the frame. In oneor more embodiments, the method includes applying an air pressuredifferential to the glass substrate while supported by the frame causingthe glass substrate to bend such that the glass substrate conforms tothe curved shape of the curved support surface of the frame, forming acurved glass substrate. The first major surface of the curved glasssubstrate includes a curved section and the second major surface of thecurved glass substrate includes a curved section. In one or moreembodiments, during application of the air pressure differential, amaximum temperature of the glass substrate is less than a glasssoftening point of the glass substrate.

Additional features and advantages will be set forth in the detaileddescription which follows, and in part will be readily apparent to thoseskilled in the art from that description or recognized by practicing theembodiments as described herein, including the detailed descriptionwhich follows, the claims, as well as the appended drawings.

It is to be understood that both the foregoing general description andthe following detailed description are merely exemplary, and areintended to provide an overview or framework to understanding the natureand character of the claims. The accompanying drawings are included toprovide a further understanding, and are incorporated in and constitutea part of this specification. The drawings illustrate one or moreembodiment(s), and together with the description serve to explainprinciples and operation of the various embodiments.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a perspective view illustration of a vehicle interior withvehicle interior systems according to one or more embodiments.

FIG. 2 is a side view illustration of a display including a curved glasssubstrate and a curved display module, according to one or moreembodiments.

FIG. 3 is a side view illustration of the glass substrate used in thedisplay of FIG. 2.

FIG. 4 is a front perspective view illustration of the glass substrateof FIG. 3.

FIG. 5 is a detailed view illustration of an embodiment of the displaymodule of FIG. 2.

FIG. 6 is a detailed view illustration of an alternative embodiment of adisplay module.

FIG. 7 is a detailed view illustration of the display of FIG. 2.

FIG. 8 is a process flow diagram of a method for forming the displayaccording to one or more embodiments.

FIG. 9 is an illustration of the method described in FIG. 8.

FIG. 10 is a flow diagram of a process for forming a display, accordingto another exemplary embodiment.

FIG. 11 is a flow diagram of a process for forming a display, accordingto another exemplary embodiment.

FIG. 12 is a detailed view of the process of FIG. 11, according toanother exemplary embodiment.

FIG. 13 is a flow diagram of a process for forming a display, accordingto another exemplary embodiment.

FIG. 14 is a perspective view of a display, according to an exemplaryembodiment.

FIG. 15 is a side view of the display of FIG. 14, according to anexemplary embodiment.

FIGS. 16A-16I are side views of a kit according to one or moreembodiments.

FIGS. 17A-17I are side views of a kit according to one or moreembodiments.

FIGS. 18A-18B are side views of a kit according to one or moreembodiments.

FIGS. 19A-19E are side view schematics illustrating one or moreembodiments of a method for forming a display.

FIG. 20A shows a perspective view of a snap-in feature of a frame.

FIG. 20B shows a front exploded view of the frame shown in FIG. 20Abefore assembly with a vehicle interior system.

FIG. 20C shows a back exploded view of the frame shown in FIG. 20Abefore assembly with a vehicle interior system.

FIG. 20D shows the assembled frame and vehicle interior system of FIGS.20B and 20C.

DETAILED DESCRIPTION

Reference will now be made in detail to various embodiments, examples ofwhich are illustrated in the accompanying drawings. In general, avehicle interior system may include a variety of different curvedsurfaces that are designed to be transparent, such as display surfaces,and the present disclosure provides articles and methods for formingthese curved surfaces from a glass material. Forming curved vehiclesurfaces from a glass material provides a number of advantages comparedto the typical curved plastic panels that are conventionally found invehicle interiors. For example, glass is typically considered to provideenhanced functionality and user experience for many curved covermaterial applications, such as display applications and touch screenapplications, compared to plastic cover materials.

Curved glass articles are typically formed using hot forming processes.As discussed herein a variety of curved glass articles and processes formaking the same are provided that avoid the deficiencies of the typicalglass hot-forming process. For example, hot-forming processes are energyintensive and increase the cost of forming a curved glass component,relative to the cold-bending process discussed herein. In addition,hot-forming processes typically make application of coatings, such asanti-reflective coatings, significantly more difficult because manycoating materials cannot be applied to a flat piece of glass materialprior to the hot-forming process as the coating material typically willnot survive the high temperatures of the hot-forming process. Further,application of a coating material to surfaces of a curved glasssubstrate after hot-bending that also meets performance requirements issubstantially more difficult than application to a flat glass substrate.In addition, by avoiding the additional high temperature heating stepsneeded for thermal forming, the glass articles produced via thecold-bending processes and systems discussed herein may have improvedoptical properties and/or improved surface properties than similarlyshaped glass articles made via thermal-shaping processes.

In addition to these advantages relative to plastic cover sheets andhot-formed cover glass, the systems and processes disclosed hereinspecifically provide for cold-bending of thin glass substrates in aneconomical and efficient process. In one or more embodiments, airpressure (e.g., a vacuum or overpressure) is used to bend the glasssubstrate to quickly and accurately conform the glass substrate to acurved frame. Further, in some specific embodiments, the systems andprocesses described herein provide for such bending and additionalcuring of bonding adhesive within common equipment and/or commonprocessing steps. In addition, the processes and systems discussedherein may also allow for attachment of the display components to theglass cover substrate during bending utilizing common equipment and/orcommon processing steps.

A first aspect of the instant application pertains to a vehicle interiorsystem. The various embodiments of the vehicle interior system may beincorporated into vehicles such as trains, automobiles (e.g., cars,trucks, buses and the like), seacraft (boats, ships, submarines, and thelike), and aircraft (e.g., drones, airplanes, jets, helicopters and thelike).

FIG. 1 illustrates an exemplary vehicle interior 10 that includes threedifferent embodiments of a vehicle interior system 100, 200, 300.Vehicle interior system 100 includes a center console base 110 with acurved surface 120 including a display 130. Vehicle interior system 200includes a dashboard base 210 with a curved surface 220 including adisplay 230. The dashboard base 210 typically includes an instrumentpanel 215 which may also include a display. Vehicle interior system 300includes a dashboard steering wheel base 310 with a curved surface 320and a display 330. In one or more embodiments, the vehicle interiorsystem may include a base that is an arm rest, a pillar, a seat back, afloor board, a headrest, a door panel, or any portion of the interior ofa vehicle that includes a curved surface.

The embodiments of the display described herein can be usedinterchangeably in each of vehicle interior systems 100, 200 and 300.Further, the curved glass substrates discussed herein may be used ascurved cover glasses for any of the display embodiments discussedherein, including for use in vehicle interior systems 100, 200 and/or300. As used herein, the term “glass substrate” is used in its broadestsense to include any object made wholly or partly of glass. Glasssubstrates include laminates of glass and non-glass materials, laminatesof glass and crystalline materials, and glass-ceramics (including anamorphous phase and a crystalline phase). The glass substrate may betransparent or opaque. In one or more embodiments, the glass substratemay include a colorant that provides a specific color.

As shown in FIG. 2, in one or more embodiments the display 130 includescold-bent curved glass substrate 140 having a first radius of curvatureand a display module 150 attached to the glass substrate, wherein atleast a portion of the display module 150 has a second radius ofcurvature that approximates or matches the first radius of curvature, toprovide a display with a curved glass substrate as a cover glass thatcan be integrated into the curved surface of a vehicle interior system.

Referring to FIGS. 3 and 4, the glass substrate 140 includes a firstmajor surface 142 and a second major surface 144 opposite the firstmajor surface. The cold-bent glass substrate exhibits the first radiusof curvature as measured on the second major surface 144.

As used herein, the terms “cold-bent,” or “cold-bending” refers tocurving the glass substrate at a cold-bend temperature which is lessthan the softening point of the glass (as described herein). The term“cold-bendable” refers to the capability of a glass substrate to becold-bent. A feature of a cold-bent glass substrate is asymmetricsurface compressive stress between the first major surface 142 and thesecond major surface 144. A minor surface 146 connects the first majorsurface 142 and the second major surface 144. In one or moreembodiments, prior to the cold-bending process or being cold-bent, therespective compressive stresses in the first major surface 142 and thesecond major surface 144 of the glass substrate are substantially equal.In one or more embodiments in which the glass substrate isunstrengthened, the first major surface 142 and the second major surface144 exhibit no appreciable compressive stress, prior to cold-bending. Inone or more embodiments in which the glass substrate is strengthened (asdescribed herein), the first major surface 142 and the second majorsurface 144 exhibit substantially equal compressive stress with respectto one another, prior to cold-bending. In one or more embodiments, aftercold-bending (shown, for example, in FIGS. 2 and 7, the compressivestress on the surface having a concave shape after bending (e.g., secondmajor surface 144 in FIGS. 2 and 7) increases. In other words, thecompressive stress on the concave surface (e.g., second major surface144) is greater after cold-bending than before cold-bending. Withoutbeing bound by theory, the cold-bending process increases thecompressive stress of the glass substrate being shaped to compensate fortensile stresses imparted during bending and/or forming operations. Inone or more embodiments, the cold-bending process causes the concavesurface (second major surface 144) to experience compressive stresses,while the surface forming a convex shape (i.e., the first major surface142 in FIGS. 2 and 7) after cold-bending experiences tensile stresses.The tensile stress experienced by the convex (i.e., the first majorsurface 142) following cold-bending results in a net decrease in surfacecompressive stress, such that the compressive stress in convex surface(i.e., the first major surface 142) of a strengthened glass substratefollowing cold-bending is less than the compressive stress on the samesurface (i.e., first major surface 142) when the glass substrate isflat.

When a strengthened glass substrate is utilized, the first major surfaceand the second major surface (142, 144) comprise a compressive stressthat is substantially equal to one another prior to cold-bending, andthus the first major surface can experience greater tensile stressduring cold-bending without risking fracture. This allows for thestrengthened glass substrate to conform to more tightly curved surfacesor shapes.

In one or more embodiments, the thickness of the glass substrate istailored to allow the glass substrate to be more flexible to achieve thedesired radius of curvature. Moreover, a thinner glass substrate 140 maydeform more readily, which could potentially compensate for shapemismatches and gaps that may be created by the shape of the displaymodule 150 (when curved). In one or more embodiments, a thin andstrengthened glass substrate 140 exhibits greater flexibility especiallyduring cold-bending. The greater flexibility of the glass substratesdiscussed herein may both allow for sufficient degrees of bending to becreated via the air pressure-based bending processes as discussed hereinand also for consistent bend formation without heating. In one or moreembodiments, the glass substrate 140 and at least a portion of thedisplay module 150 have substantially similar radii of curvature toprovide a substantially uniform distance between the first major surface142 and the display module 150 (which may be filled with an adhesive).

In one or more embodiments, the cold-bent glass substrate (andoptionally the curved display module) may have a compound curveincluding a major radius and a cross curvature. A complexly curvedcold-bent glass substrate (and optionally the curved display module)according to one or more embodiments may have a distinct radius ofcurvature in two independent directions. According to one or moreembodiments, the complexly curved cold-bent glass substrate (andoptionally the curved display module) may thus be characterized ashaving “cross curvature,” where the cold-bent glass substrate (andoptionally the curved display module) are curved along an axis (i.e., afirst axis) that is parallel to a given dimension and also curved alongan axis (i.e., a second axis) that is perpendicular to the samedimension. The curvature of the cold-bent glass substrate (andoptionally the curved display module) can be even more complex when asignificant minimum radius is combined with a significant crosscurvature, and/or depth of bend.

In the embodiment shown, the glass substrate has a thickness (t) that issubstantially constant and is defined as a distance between the firstmajor surface 142 and the second major surface 144. The thickness (t) asused herein refers to the maximum thickness of the glass substrate. Inthe embodiment shown in FIGS. 3-4, the glass substrate includes a width(W) defined as a first maximum dimension of one of the first or secondmajor surfaces orthogonal to the thickness (t), and a length (L) definedas a second maximum dimension of one of the first or second surfacesorthogonal to both the thickness and the width. In other embodiments,the dimensions discussed herein may be average dimensions.

In one or more embodiments, the glass substrate has a thickness (t) thatis about 1.5 mm or less. For example, the thickness may be in a rangefrom about 0.01 mm to about 1.5 mm, 0.02 mm to about 1.5 mm, 0.03 mm toabout 1.5 mm, 0.04 mm to about 1.5 mm, 0.05 mm to about 1.5 mm, 0.06 mmto about 1.5 mm, 0.07 mm to about 1.5 mm, 0.08 mm to about 1.5 mm, 0.09mm to about 1.5 mm, 0.1 mm to about 1.5 mm, from about 0.15 mm to about1.5 mm, from about 0.2 mm to about 1.5 mm, from about 0.25 mm to about1.5 mm, from about 0.3 mm to about 1.5 mm, from about 0.35 mm to about1.5 mm, from about 0.4 mm to about 1.5 mm, from about 0.45 mm to about1.5 mm, from about 0.5 mm to about 1.5 mm, from about 0.55 mm to about1.5 mm, from about 0.6 mm to about 1.5 mm, from about 0.65 mm to about1.5 mm, from about 0.7 mm to about 1.5 mm, from about 0.01 mm to about1.4 mm, from about 0.01 mm to about 1.3 mm, from about 0.01 mm to about1.2 mm, from about 0.01 mm to about 1.1 mm, from about 0.01 mm to about1.05 mm, from about 0.01 mm to about 1 mm, from about 0.01 mm to about0.95 mm, from about 0.01 mm to about 0.9 mm, from about 0.01 mm to about0.85 mm, from about 0.01 mm to about 0.8 mm, from about 0.01 mm to about0.75 mm, from about 0.01 mm to about 0.7 mm, from about 0.01 mm to about0.65 mm, from about 0.01 mm to about 0.6 mm, from about 0.01 mm to about0.55 mm, from about 0.01 mm to about 0.5 mm, from about 0.01 mm to about0.4 mm, from about 0.01 mm to about 0.3 mm, from about 0.01 mm to about0.2 mm, from about 0.01 mm to about 0.1 mm, from about 0.04 mm to about0.07 mm, from about 0.1 mm to about 1.4 mm, from about 0.1 mm to about1.3 mm, from about 0.1 mm to about 1.2 mm, from about 0.1 mm to about1.1 mm, from about 0.1 mm to about 1.05 mm, from about 0.1 mm to about 1mm, from about 0.1 mm to about 0.95 mm, from about 0.1 mm to about 0.9mm, from about 0.1 mm to about 0.85 mm, from about 0.1 mm to about 0.8mm, from about 0.1 mm to about 0.75 mm, from about 0.1 mm to about 0.7mm, from about 0.1 mm to about 0.65 mm, from about 0.1 mm to about 0.6mm, from about 0.1 mm to about 0.55 mm, from about 0.1 mm to about 0.5mm, from about 0.1 mm to about 0.4 mm, or from about 0.3 mm to about 0.7mm.

In one or more embodiments, the glass substrate has a width (W) in arange from about 5 cm to about 250 cm, from about 10 cm to about 250 cm,from about 15 cm to about 250 cm, from about 20 cm to about 250 cm, fromabout 25 cm to about 250 cm, from about 30 cm to about 250 cm, fromabout 35 cm to about 250 cm, from about 40 cm to about 250 cm, fromabout 45 cm to about 250 cm, from about 50 cm to about 250 cm, fromabout 55 cm to about 250 cm, from about 60 cm to about 250 cm, fromabout 65 cm to about 250 cm, from about 70 cm to about 250 cm, fromabout 75 cm to about 250 cm, from about 80 cm to about 250 cm, fromabout 85 cm to about 250 cm, from about 90 cm to about 250 cm, fromabout 95 cm to about 250 cm, from about 100 cm to about 250 cm, fromabout 110 cm to about 250 cm, from about 120 cm to about 250 cm, fromabout 130 cm to about 250 cm, from about 140 cm to about 250 cm, fromabout 150 cm to about 250 cm, from about 5 cm to about 240 cm, fromabout 5 cm to about 230 cm, from about 5 cm to about 220 cm, from about5 cm to about 210 cm, from about 5 cm to about 200 cm, from about 5 cmto about 190 cm, from about 5 cm to about 180 cm, from about 5 cm toabout 170 cm, from about 5 cm to about 160 cm, from about 5 cm to about150 cm, from about 5 cm to about 140 cm, from about 5 cm to about 130cm, from about 5 cm to about 120 cm, from about 5 cm to about 110 cm,from about 5 cm to about 110 cm, from about 5 cm to about 100 cm, fromabout 5 cm to about 90 cm, from about 5 cm to about 80 cm, or from about5 cm to about 75 cm.

In one or more embodiments, the glass substrate has a length (L) in arange from about 5 cm to about 250 cm, from about 10 cm to about 250 cm,from about 15 cm to about 250 cm, from about 20 cm to about 250 cm, fromabout 25 cm to about 250 cm, from about 30 cm to about 250 cm, fromabout 35 cm to about 250 cm, from about 40 cm to about 250 cm, fromabout 45 cm to about 250 cm, from about 50 cm to about 250 cm, fromabout 55 cm to about 250 cm, from about 60 cm to about 250 cm, fromabout 65 cm to about 250 cm, from about 70 cm to about 250 cm, fromabout 75 cm to about 250 cm, from about 80 cm to about 250 cm, fromabout 85 cm to about 250 cm, from about 90 cm to about 250 cm, fromabout 95 cm to about 250 cm, from about 100 cm to about 250 cm, fromabout 110 cm to about 250 cm, from about 120 cm to about 250 cm, fromabout 130 cm to about 250 cm, from about 140 cm to about 250 cm, fromabout 150 cm to about 250 cm, from about 5 cm to about 240 cm, fromabout 5 cm to about 230 cm, from about 5 cm to about 220 cm, from about5 cm to about 210 cm, from about 5 cm to about 200 cm, from about 5 cmto about 190 cm, from about 5 cm to about 180 cm, from about 5 cm toabout 170 cm, from about 5 cm to about 160 cm, from about 5 cm to about150 cm, from about 5 cm to about 140 cm, from about 5 cm to about 130cm, from about 5 cm to about 120 cm, from about 5 cm to about 110 cm,from about 5 cm to about 110 cm, from about 5 cm to about 100 cm, fromabout 5 cm to about 90 cm, from about 5 cm to about 80 cm, or from about5 cm to about 75 cm.

In one or more embodiments, the glass substrate may be strengthened. Inone or more embodiments, the glass substrate may be strengthened toinclude compressive stress that extends from a surface to a depth ofcompression (DOC). The compressive stress regions are balanced by acentral portion exhibiting a tensile stress. At the DOC, the stresscrosses from a compressive stress to a tensile stress. The compressivestress and the tensile stress are provided herein as absolute values.

In one or more embodiments, the glass substrate may be strengthenedmechanically by utilizing a mismatch of the coefficient of thermalexpansion between portions of the article to create a compressive stressregion and a central region exhibiting a tensile stress. In someembodiments, the glass substrate may be strengthened thermally byheating the glass to a temperature above the glass transition point andthen rapidly quenching.

In one or more embodiments, the glass substrate may be chemicallystrengthening by ion exchange. In the ion exchange process, ions at ornear the surface of the glass substrate are replaced by—or exchangedwith—larger ions having the same valence or oxidation state. In thoseembodiments in which the glass substrate comprises an alkalialuminosilicate glass, ions in the surface layer of the article and thelarger ions are monovalent alkali metal cations, such as Li⁺, Na⁺, K⁺,Rb⁺, and Cs⁺. Alternatively, monovalent cations in the surface layer maybe replaced with monovalent cations other than alkali metal cations,such as Ag⁺ or the like. In such embodiments, the monovalent ions (orcations) exchanged into the glass substrate generate a stress.

Ion exchange processes are typically carried out by immersing a glasssubstrate in a molten salt bath (or two or more molten salt baths)containing the larger ions to be exchanged with the smaller ions in theglass substrate. It should be noted that aqueous salt baths may also beutilized. In addition, the composition of the bath(s) may include morethan one type of larger ion (e.g., Na+ and K+) or a single larger ion.It will be appreciated by those skilled in the art that parameters forthe ion exchange process, including, but not limited to, bathcomposition and temperature, immersion time, the number of immersions ofthe glass substrate in a salt bath (or baths), use of multiple saltbaths, additional steps such as annealing, washing, and the like, aregenerally determined by the composition of the glass substrate(including the structure of the article and any crystalline phasespresent) and the desired DOC and CS of the glass substrate that resultsfrom strengthening. Exemplary molten bath composition may includenitrates, sulfates, and chlorides of the larger alkali metal ion.Typical nitrates include KNO₃, NaNO₃, LiNO₃, NaSO₄ and combinationsthereof. The temperature of the molten salt bath typically is in a rangefrom about 380° C. up to about 450° C., while immersion times range fromabout 15 minutes up to about 100 hours depending on glass substratethickness, bath temperature and glass (or monovalent ion) diffusivity.However, temperatures and immersion times different from those describedabove may also be used.

In one or more embodiments, the glass substrates may be immersed in amolten salt bath of 100% NaNO₃, 100% KNO₃, or a combination of NaNO₃ andKNO₃ having a temperature from about 370° C. to about 480° C. In someembodiments, the glass substrate may be immersed in a molten mixed saltbath including from about 1% to about 99% KNO₃ and from about 1% toabout 99% NaNO₃. In one or more embodiments, the glass substrate may beimmersed in a second bath, after immersion in a first bath. The firstand second baths may have different compositions and/or temperaturesfrom one another. The immersion times in the first and second baths mayvary. For example, immersion in the first bath may be longer than theimmersion in the second bath.

In one or more embodiments, the glass substrate may be immersed in amolten, mixed salt bath including NaNO₃ and KNO₃ (e.g., 49%/51%,50%/50%, 51%/49%) having a temperature less than about 420° C. (e.g.,about 400° C. or about 380° C.). for less than about 5 hours, or evenabout 4 hours or less.

Ion exchange conditions can be tailored to provide a “spike” or toincrease the slope of the stress profile at or near the surface of theresulting glass substrate. The spike may result in a greater surface CSvalue. This spike can be achieved by single bath or multiple baths, withthe bath(s) having a single composition or mixed composition, due to theunique properties of the glass compositions used in the glass substratesdescribed herein.

In one or more embodiments, where more than one monovalent ion isexchanged into the glass substrate, the different monovalent ions mayexchange to different depths within the glass substrate (and generatedifferent magnitudes stresses within the glass substrate at differentdepths). The resulting relative depths of the stress-generating ions canbe determined and cause different characteristics of the stress profile.

CS is measured using those means known in the art, such as by surfacestress meter (FSM) using commercially available instruments such as theFSM-6000, manufactured by Orihara Industrial Co., Ltd. (Japan). Surfacestress measurements rely upon the accurate measurement of the stressoptical coefficient (SOC), which is related to the birefringence of theglass. SOC in turn is measured by those methods that are known in theart, such as fiber and four point bend methods, both of which aredescribed in ASTM standard C770-98 (2013), entitled “Standard TestMethod for Measurement of Glass Stress-Optical Coefficient,” thecontents of which are incorporated herein by reference in theirentirety, and a bulk cylinder method. As used herein CS may be the“maximum compressive stress” which is the highest compressive stressvalue measured within the compressive stress layer. In some embodiments,the maximum compressive stress is located at the surface of the glasssubstrate. In other embodiments, the maximum compressive stress mayoccur at a depth below the surface, giving the compressive profile theappearance of a “buried peak.”

DOC may be measured by FSM or by a scattered light polariscope (SCALP)(such as the SCALP-04 scattered light polariscope available fromGlasstress Ltd., located in Tallinn Estonia), depending on thestrengthening method and conditions. When the glass substrate ischemically strengthened by an ion exchange treatment, FSM or SCALP maybe used depending on which ion is exchanged into the glass substrate.Where the stress in the glass substrate is generated by exchangingpotassium ions into the glass substrate, FSM is used to measure DOC.Where the stress is generated by exchanging sodium ions into the glasssubstrate, SCALP is used to measure DOC. Where the stress in the glasssubstrate is generated by exchanging both potassium and sodium ions intothe glass, the DOC is measured by SCALP, since it is believed theexchange depth of sodium indicates the DOC and the exchange depth ofpotassium ions indicates a change in the magnitude of the compressivestress (but not the change in stress from compressive to tensile); theexchange depth of potassium ions in such glass substrates is measured byFSM. Central tension or CT is the maximum tensile stress and is measuredby SCALP.

In one or more embodiments, the glass substrate maybe strengthened toexhibit a DOC that is described a fraction of the thickness t of theglass substrate (as described herein). For example, in one or moreembodiments, the DOC may be equal to or greater than about 0.05t, equalto or greater than about 0.1t, equal to or greater than about 0.11t,equal to or greater than about 0.12t, equal to or greater than about0.13t, equal to or greater than about 0.14t, equal to or greater thanabout 0.15t, equal to or greater than about 0.16t, equal to or greaterthan about 0.17t, equal to or greater than about 0.18t, equal to orgreater than about 0.19t, equal to or greater than about 0.2t, equal toor greater than about 0.21t. In some embodiments, The DOC may be in arange from about 0.08t to about 0.25t, from about 0.09t to about 0.25t,from about 0.18t to about 0.25t, from about 0.11t to about 0.25t, fromabout 0.12t to about 0.25t, from about 0.13t to about 0.25t, from about0.14t to about 0.25t, from about 0.15t to about 0.25t, from about 0.08tto about 0.24t, from about 0.08t to about 0.23t, from about 0.08t toabout 0.22t, from about 0.08t to about 0.21t, from about 0.08t to about0.2t, from about 0.08t to about 0.19t, from about 0.08t to about 0.18t,from about 0.08t to about 0.17t, from about 0.08t to about 0.16t, orfrom about 0.08t to about 0.15t. In some instances, the DOC may be about20 μm or less. In one or more embodiments, the DOC may be about 40 μm orgreater (e.g., from about 40 μm to about 300 μm, from about 50 μm toabout 300 μm, from about 60 μm to about 300 μm, from about 70 μm toabout 300 μm, from about 80 μm to about 300 μm, from about 90 μm toabout 300 μm, from about 100 μm to about 300 μm, from about 110 μm toabout 300 μm, from about 120 μm to about 300 μm, from about 140 μm toabout 300 μm, from about 150 μm to about 300 μm, from about 40 μm toabout 290 μm, from about 40 μm to about 280 μm, from about 40 μm toabout 260 μm, from about 40 μm to about 250 μm, from about 40 μm toabout 240 μm, from about 40 μm to about 230 μm, from about 40 μm toabout 220 μm, from about 40 μm to about 210 μm, from about 40 μm toabout 200 μm, from about 40 μm to about 180 μm, from about 40 μm toabout 160 μm, from about 40 μm to about 150 μm, from about 40 μm toabout 140 μm, from about 40 μm to about 130 μm, from about 40 μm toabout 120 μm, from about 40 μm to about 110 μm, or from about 40 μm toabout 100 μm.

In one or more embodiments, the strengthened glass substrate may have aCS (which may be found at the surface or a depth within the glasssubstrate) of about 200 MPa or greater, 300 MPa or greater, 400 MPa orgreater, about 500 MPa or greater, about 600 MPa or greater, about 700MPa or greater, about 800 MPa or greater, about 900 MPa or greater,about 930 MPa or greater, about 1000 MPa or greater, or about 1050 MPaor greater. In one or more embodiments, the strengthened glass substratemay have a CS (which may be found at the surface or a depth within theglass substrate) from about 200 MPa to about 1050 MPa, from about 250MPa to about 1050 MPa, from about 300 MPa to about 1050 MPa, from about350 MPa to about 1050 MPa, from about 400 MPa to about 1050 MPa, fromabout 450 MPa to about 1050 MPa, from about 500 MPa to about 1050 MPa,from about 550 MPa to about 1050 MPa, from about 600 MPa to about 1050MPa, from about 200 MPa to about 1000 MPa, from about 200 MPa to about950 MPa, from about 200 MPa to about 900 MPa, from about 200 MPa toabout 850 MPa, from about 200 MPa to about 800 MPa, from about 200 MPato about 750 MPa, from about 200 MPa to about 700 MPa, from about 200MPa to about 650 MPa, from about 200 MPa to about 600 MPa, from about200 MPa to about 550 MPa, or from about 200 MPa to about 500 MPa.

In one or more embodiments, the strengthened glass substrate may have amaximum tensile stress or central tension (CT) of about 20 MPa orgreater, about 30 MPa or greater, about 40 MPa or greater, about 45 MPaor greater, about 50 MPa or greater, about 60 MPa or greater, about 70MPa or greater, about 75 MPa or greater, about 80 MPa or greater, orabout 85 MPa or greater. In some embodiments, the maximum tensile stressor central tension (CT) may be in a range from about 40 MPa to about 100MPa, from about 50 MPa to about 100 MPa, from about 60 MPa to about 100MPa, from about 70 MPa to about 100 MPa, from about 80 MPa to about 100MPa, from about 40 MPa to about 90 MPa, from about 40 MPa to about 80MPa, from about 40 MPa to about 70 MPa, or from about 40 MPa to about 60MPa.

In some embodiments, the strengthened glass substrate exhibits a stressprofile along the depth or thickness thereof that exhibits aparabolic-like shape, as described in U.S. Pat. No. 9,593,042, entitled“Glasses and glass ceramics including metal oxide concentrationgradient”, which is hereby incorporated by reference in its entirety.“Stress profile” refers to the changes in stress from the first majorsurface to the second major surface. The stress profile may be describedin terms of MPa at a given micrometer of thickness or depth from thefirst major surface or the second major surface. In one or more specificembodiments, the stress profile is substantially free of a flat stress(i.e., compressive or tensile) portion or a portion that exhibits asubstantially constant stress (i.e., compressive or tensile). In someembodiments, the region of the glass substrate exhibiting a tensilestress has a stress profile that is substantially free of a flat stressor free of a substantially constant stress. In one or more embodiments,all points of the stress profile between a thickness range from about 0tup to about 0.2·t and greater than 0.8·t (or from about 0·t to about0.3·t and greater than 0.7·t) comprise a tangent that is less than about−0.1 MPa/micrometers or greater than about 0.1 MPa/micrometers. In someembodiments, the tangent may be less than about −0.2 MPa/micrometers orgreater than about 0.2 MPa/micrometers. In some more specificembodiments, the tangent may be less than about −0.3 MPa/micrometers orgreater than about 0.3 MPa/micrometers. In an even more specificembodiment, the tangent may be less than about −0.5 MPa/micrometers orgreater than about 0.5 MPa/micrometers. In other words, the stressprofile of one or more embodiments along these thickness ranges (i.e.,0·t up to about 2·t and greater than 0.8t, or from about 0t to about0.3·t and 0.7·t or greater) exclude points having a tangent, asdescribed herein. In contrast, stress profiles that exhibit errorfunction or quasi-linear shapes have points along these thickness ranges(i.e., 0·t up to about 2·t and greater than 0.8·t, or from about 0·t toabout 0.3·t and 0.7·t or greater) that have a tangent that is from about−0.1 MPa/micrometers to about 0.1 MPa/micrometers, from about −0.2MPa/micrometers to about 0.2 MPa/micrometers, from about −0.3MPa/micrometers to about 0.3 MPa/micrometers, or from about −0.5MPa/micrometers to about 0.5 MPa/micrometers (indicating a flat or zeroslope stress profile along such thickness ranges, as shown in FIG. 2,220). The stress profiles of one or more embodiments of this disclosuredo not exhibit such a stress profile having a flat or zero slope stressprofile along these thickness ranges.

In one or more embodiments, the strengthened glass substrate exhibits astress profile a thickness range from about 0.1·t to 0.3·t and fromabout 0.7·t to 0.9·t that comprises a maximum tangent and a minimumtangent. In some instances, the difference between the maximum tangentand the minimum tangent is about 3.5 MPa/micrometers or less, about 3MPa/micrometers or less, about 2.5 MPa/micrometers or less, or about 2MPa/micrometers or less.

In one or more embodiments, the stress profile of the strengthened glasssubstrate may be substantially free of any linear segments that extendin a depth direction or along at least a portion of the thickness t ofthe glass substrate. In other words, the stress profile is substantiallycontinuously increasing or decreasing along the thickness t. In someembodiments, the stress profile is substantially free of any linearsegments in a depth or thickness direction having a length of about 10micrometers or more, about 50 micrometers or more, or about 100micrometers or more, or about 200 micrometers or more. As used herein,the term “linear” refers to a slope having a magnitude of less thanabout 5 MPa/micrometer, or less than about 2 MPa/micrometer along thelinear segment. In some embodiments, one or more portions of the stressprofile that are substantially free of any linear segments in a depthdirection are present at depths within the strengthened glass substrateof about 5 micrometers or greater (e.g., 10 micrometers or greater, or15 micrometers or greater) from either one or both the first majorsurface or the second major surface. For example, along a depth orthickness of about 0 micrometers to less than about 5 micrometers fromthe first surface, the stress profile may include linear segments, butfrom a depth of about 5 micrometers or greater from the first surface,the stress profile may be substantially free of linear segments.

In some embodiments, the stress profile may include linear segments atdepths from about 0t up to about 0.1t and may be substantially free oflinear segments at depths of about 0.1t to about 0.4t. In someembodiments, the stress profile from a thickness in the range from about0t to about 0.1t may have a slope in the range from about 20 MPa/micronsto about 200 MPa/microns. As will be described herein, such embodimentsmay be formed using a single ion-exchange process by which the bathincludes two or more alkali salts or is a mixed alkali salt bath ormultiple (e.g., 2 or more) ion exchange processes.

In one or more embodiments, the strengthened glass substrate may bedescribed in terms of the shape of the stress profile along the CTregion or the region in the glass substrate that exhibits tensilestress. For example, in some embodiments, the stress profile along theCT region (where stress is in tension) may be approximated by equation.In some embodiments, the stress profile along the CT region may beapproximated by equation (1):Stress(x)=MaxCT−(((MaxCT·(n+1))/0.5^(n))·|(x/t)−0.5|^(n))  (1)In equation (1), the stress (x) is the stress value at position x. Herethe stress is positive (tension). MaxCT is the maximum central tensionas a positive value in MPa. The value x is position along the thickness(t) in micrometers, with a range from 0 to t; x=0 is one surface (302,in FIG. 3), x=0.5t is the center of the glass substrate,stress(x)=MaxCT, and x=t is the opposite surface (i.e., the first majorsurface or the second major surface). MaxCT used in equation (1) may bein the range from about 50 MPa to about 350 MPa (e.g., 60 MPa to about300 MPa, or from about 70 MPa to about 270 MPa), and n is a fittingparameter from 1.5 to 5 (e.g., 2 to 4, 2 to 3 or 1.8 to 2.2) whereby n=2can provide a parabolic stress profile, exponents that deviate from n=2provide stress profiles with near parabolic stress profiles.

In one or more embodiments, the parabolic-like stress profile isgenerated due to a non-zero concentration of a metal oxide(s) thatvaries along a portion of the thickness. The variation in concentrationmay be referred to herein as a gradient. In some embodiments, theconcentration of a metal oxide is non-zero and varies, both along athickness range from about 0·t to about 0.3·t. In some embodiments, theconcentration of the metal oxide is non-zero and varies along athickness range from about 0·t to about 0.35·t, from about 0·t to about0.4·t, from about 0·t to about 0.45·t or from about 0·t to about 0.48·t.The metal oxide may be described as generating a stress in thestrengthened glass substrate. The variation in concentration may becontinuous along the above-referenced thickness ranges. Variation inconcentration may include a change in metal oxide concentration of about0.2 mol % along a thickness segment of about 100 micrometers. Thischange may be measured by known methods in the art including microprobe.The metal oxide that is non-zero in concentration and varies along aportion of the thickness may be described as generating a stress in thestrengthened glass substrate.

The variation in concentration may be continuous along theabove-referenced thickness ranges. In some embodiments, the variation inconcentration may be continuous along thickness segments in the rangefrom about 10 micrometers to about 30 micrometers. In some embodiments,the concentration of the metal oxide decreases from the first surface toa point between the first surface and the second surface and increasesfrom the point to the second surface.

The concentration of metal oxide may include more than one metal oxide(e.g., a combination of Na₂O and K₂O). In some embodiments, where twometal oxides are utilized and where the radius of the ions differ fromone or another, the concentration of ions having a larger radius isgreater than the concentration of ions having a smaller radius atshallow depths, while the at deeper depths, the concentration of ionshaving a smaller radius is greater than the concentration of ions havinglarger radius. For example, where a single Na- and K-containing bath isused in the ion exchange process, the concentration of K+ ions in thestrengthened glass substrate is greater than the concentration of Na+ions at shallower depths, while the concentration of Na+ is greater thanthe concentration of K+ ions at deeper depths. This is due, in part, dueto the size of the ions. In such strengthened glass substrate, the areaat or near the surface comprises a greater CS due to the greater amountof larger ions at or near the surface. This greater CS may be exhibitedby a stress profile having a steeper slope at or near the surface (i.e.,a spike in the stress profile at the surface).

The concentration gradient or variation of one or more metal oxides iscreated by chemically strengthening the glass substrate, for example, bythe ion exchange processes previously described herein, in which aplurality of first metal ions in the glass substrate is exchanged with aplurality of second metal ions. The first ions may be ions of lithium,sodium, potassium, and rubidium. The second metal ions may be ions ofone of sodium, potassium, rubidium, and cesium, with the proviso thatthe second alkali metal ion has an ionic radius greater than the ionicradius than the first alkali metal ion. The second metal ion is presentin the glass substrate as an oxide thereof (e.g., Na₂O, K₂O, Rb₂O, Cs₂Oor a combination thereof).

In one or more embodiments, the metal oxide concentration gradientextends through a substantial portion of the thickness t or the entirethickness t of the strengthened glass substrate, including the CTregion. In one or more embodiments, the concentration of the metal oxideis about 0.5 mol % or greater in the CT region. In some embodiments, theconcentration of the metal oxide may be about 0.5 mol % or greater(e.g., about 1 mol % or greater) along the entire thickness of thestrengthened glass substrate, and is greatest at the first major surfaceand/or the second major surface and decreases substantially constantlyto a point between the first major surface and the second major surface.At that point, the concentration of the metal oxide is the least alongthe entire thickness t; however the concentration is also non-zero atthat point. In other words, the non-zero concentration of thatparticular metal oxide extends along a substantial portion of thethickness t (as described herein) or the entire thickness t. In someembodiments, the lowest concentration in the particular metal oxide isin the CT region. The total concentration of the particular metal oxidein the strengthened glass substrate may be in the range from about 1 mol% to about 20 mol %.

In one or more embodiments, the strengthened glass substrate includes afirst metal oxide concentration and a second metal oxide concentration,such that the first metal oxide concentration is in the range from about0 mol % to about 15 mol % along a first thickness range from about 0t toabout 0.5t, and the second metal oxide concentration is in the rangefrom about 0 mol % to about 10 mol % from a second thickness range fromabout 0 micrometers to about 25 micrometers (or from about 0 micrometersto about 12 micrometers). The strengthened glass substrate may includean optional third metal oxide concentration. The first metal oxide mayinclude Na₂O while the second metal oxide may include K2O.

The concentration of the metal oxide may be determined from a baselineamount of the metal oxide in the glass substrate prior to being modifiedto include the concentration gradient of such metal oxide.

Suitable glass compositions for use in the glass substrate include sodalime glass, aluminosilicate glass, borosilicate glass,boroaluminosilicate glass, alkali-containing aluminosilicate glass,alkali-containing borosilicate glass, and alkali-containingboroaluminosilicate glass.

Unless otherwise specified, the glass compositions disclosed herein aredescribed in mole percent (mol %) as analyzed on an oxide basis.

In one or more embodiments, the glass composition may include SiO₂ in anamount in a range from about 66 mol % to about 80 mol %, from about 67mol % to about 80 mol %, from about 68 mol % to about 80 mol %, fromabout 69 mol % to about 80 mol %, from about 70 mol % to about 80 mol %,from about 72 mol % to about 80 mol %, from about 65 mol % to about 78mol %, from about 65 mol % to about 76 mol %, from about 65 mol % toabout 75 mol %, from about 65 mol % to about 74 mol %, from about 65 mol% to about 72 mol %, or from about 65 mol % to about 70 mol %, and allranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes Al₂O₃ in anamount greater than about 4 mol %, or greater than about 5 mol %. In oneor more embodiments, the glass composition includes Al₂O₃ in a rangefrom greater than about 7 mol % to about 15 mol %, from greater thanabout 7 mol % to about 14 mol %, from about 7 mol % to about 13 mol %,from about 4 mol % to about 12 mol %, from about 7 mol % to about 11 mol%, from about 8 mol % to about 15 mol %, from 9 mol % to about 15 mol %,from about 9 mol % to about 15 mol %, from about 10 mol % to about 15mol %, from about 11 mol % to about 15 mol %, or from about 12 mol % toabout 15 mol %, and all ranges and sub-ranges therebetween. In one ormore embodiments, the upper limit of Al₂O₃ may be about 14 mol %, 14.2mol %, 14.4 mol %, 14.6 mol %, or 14.8 mol %.

In one or more embodiments, the glass article is described as analuminosilicate glass article or including an aluminosilicate glasscomposition. In such embodiments, the glass composition or articleformed therefrom includes SiO₂ and Al₂O₃ and is not a soda lime silicateglass. In this regard, the glass composition or article formed therefromincludes Al₂O₃ in an amount of about 2 mol % or greater, 2.25 mol % orgreater, 2.5 mol % or greater, about 2.75 mol % or greater, about 3 mol% or greater.

In one or more embodiments, the glass composition comprises B₂O₃ (e.g.,about 0.01 mol % or greater). In one or more embodiments, the glasscomposition comprises B₂O₃ in an amount in a range from about 0 mol % toabout 5 mol %, from about 0 mol % to about 4 mol %, from about 0 mol %to about 3 mol %, from about 0 mol % to about 2 mol %, from about 0 mol% to about 1 mol %, from about 0 mol % to about 0.5 mol %, from about0.1 mol % to about 5 mol %, from about 0.1 mol % to about 4 mol %, fromabout 0.1 mol % to about 3 mol %, from about 0.1 mol % to about 2 mol %,from about 0.1 mol % to about 1 mol %, from about 0.1 mol % to about 0.5mol %, and all ranges and sub-ranges therebetween. In one or moreembodiments, the glass composition is substantially free of B₂O₃.

As used herein, the phrase “substantially free” with respect to thecomponents of the composition means that the component is not activelyor intentionally added to the composition during initial batching, butmay be present as an impurity in an amount less than about 0.001 mol %.

In one or more embodiments, the glass composition optionally comprisesP₂O₅ (e.g., about 0.01 mol % or greater). In one or more embodiments,the glass composition comprises a non-zero amount of P₂O₅ up to andincluding 2 mol %, 1.5 mol %, 1 mol %, or 0.5 mol %. In one or moreembodiments, the glass composition is substantially free of P₂O₅.

In one or more embodiments, the glass composition may include a totalamount of R₂O (which is the total amount of alkali metal oxide such asLi₂O, Na₂O, K₂O, Rb₂O, and Cs₂O) that is greater than or equal to about8 mol %, greater than or equal to about 10 mol %, or greater than orequal to about 12 mol %. In some embodiments, the glass compositionincludes a total amount of R₂O in a range from about 8 mol % to about 20mol %, from about 8 mol % to about 18 mol %, from about 8 mol % to about16 mol %, from about 8 mol % to about 14 mol %, from about 8 mol % toabout 12 mol %, from about 9 mol % to about 20 mol %, from about 10 mol% to about 20 mol %, from about 11 mol % to about 20 mol %, from about12 mol % to about 20 mol %, from about 13 mol % to about 20 mol %, fromabout 10 mol % to about 14 mol %, or from 11 mol % to about 13 mol %,and all ranges and sub-ranges therebetween. In one or more embodiments,the glass composition may be substantially free of Rb₂O, Cs₂O or bothRb₂O and Cs₂O. In one or more embodiments, the R₂O may include the totalamount of Li₂O, Na₂O and K₂O only. In one or more embodiments, the glasscomposition may comprise at least one alkali metal oxide selected fromLi₂O, Na₂O and K₂O, wherein the alkali metal oxide is present in anamount greater than about 8 mol % or greater.

In one or more embodiments, the glass composition comprises Na₂O in anamount greater than or equal to about 8 mol %, greater than or equal toabout 10 mol %, or greater than or equal to about 12 mol %. In one ormore embodiments, the composition includes Na₂O in a range from aboutfrom about 8 mol % to about 20 mol %, from about 8 mol % to about 18 mol%, from about 8 mol % to about 16 mol %, from about 8 mol % to about 14mol %, from about 8 mol % to about 12 mol %, from about 9 mol % to about20 mol %, from about 10 mol % to about 20 mol %, from about 11 mol % toabout 20 mol %, from about 12 mol % to about 20 mol %, from about 13 mol% to about 20 mol %, from about 10 mol % to about 14 mol %, or from 11mol % to about 16 mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes less thanabout 4 mol % K₂O, less than about 3 mol % K₂O, or less than about 1 mol% K₂O. In some instances, the glass composition may include K₂O in anamount in a range from about 0 mol % to about 4 mol %, from about 0 mol% to about 3.5 mol %, from about 0 mol % to about 3 mol %, from about 0mol % to about 2.5 mol %, from about 0 mol % to about 2 mol %, fromabout 0 mol % to about 1.5 mol %, from about 0 mol % to about 1 mol %,from about 0 mol % to about 0.5 mol %, from about 0 mol % to about 0.2mol %, from about 0 mol % to about 0.1 mol %, from about 0.5 mol % toabout 4 mol %, from about 0.5 mol % to about 3.5 mol %, from about 0.5mol % to about 3 mol %, from about 0.5 mol % to about 2.5 mol %, fromabout 0.5 mol % to about 2 mol %, from about 0.5 mol % to about 1.5 mol%, or from about 0.5 mol % to about 1 mol %, and all ranges andsub-ranges therebetween. In one or more embodiments, the glasscomposition may be substantially free of K₂O.

In one or more embodiments, the glass composition is substantially freeof Li₂O.

In one or more embodiments, the amount of Na₂O in the composition may begreater than the amount of Li₂O. In some instances, the amount of Na₂Omay be greater than the combined amount of Li₂O and K₂O. In one or morealternative embodiments, the amount of Li₂O in the composition may begreater than the amount of Na₂O or the combined amount of Na₂O and K₂O.

In one or more embodiments, the glass composition may include a totalamount of RO (which is the total amount of alkaline earth metal oxidesuch as CaO, MgO, BaO, ZnO and SrO) in a range from about 0 mol % toabout 2 mol %. In some embodiments, the glass composition includes anon-zero amount of RO up to about 2 mol %. In one or more embodiments,the glass composition comprises RO in an amount from about 0 mol % toabout 1.8 mol %, from about 0 mol % to about 1.6 mol %, from about 0 mol% to about 1.5 mol %, from about 0 mol % to about 1.4 mol %, from about0 mol % to about 1.2 mol %, from about 0 mol % to about 1 mol %, fromabout 0 mol % to about 0.8 mol %, from about 0 mol % to about 0.5 mol %,and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition includes CaO in anamount less than about 1 mol %, less than about 0.8 mol %, or less thanabout 0.5 mol %. In one or more embodiments, the glass composition issubstantially free of CaO.

In some embodiments, the glass composition comprises MgO in an amountfrom about 0 mol % to about 7 mol %, from about 0 mol % to about 6 mol%, from about 0 mol % to about 5 mol %, from about 0 mol % to about 4mol %, from about 0.1 mol % to about 7 mol %, from about 0.1 mol % toabout 6 mol %, from about 0.1 mol % to about 5 mol %, from about 0.1 mol% to about 4 mol %, from about 1 mol % to about 7 mol %, from about 2mol % to about 6 mol %, or from about 3 mol % to about 6 mol %, and allranges and sub-ranges therebetween.

In one or more embodiments, the glass composition comprises ZrO₂ in anamount equal to or less than about 0.2 mol %, less than about 0.18 mol%, less than about 0.16 mol %, less than about 0.15 mol %, less thanabout 0.14 mol %, less than about 0.12 mol %. In one or moreembodiments, the glass composition comprises ZrO₂ in a range from about0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18 mol%, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol % toabout 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, from about0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about 0.10mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition comprises SnO₂ in anamount equal to or less than about 0.2 mol %, less than about 0.18 mol%, less than about 0.16 mol %, less than about 0.15 mol %, less thanabout 0.14 mol %, less than about 0.12 mol %. In one or moreembodiments, the glass composition comprises SnO2 in a range from about0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18 mol%, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol % toabout 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, from about0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about 0.10mol %, and all ranges and sub-ranges therebetween.

In one or more embodiments, the glass composition may include an oxidethat imparts a color or tint to the glass articles. In some embodiments,the glass composition includes an oxide that prevents discoloration ofthe glass article when the glass article is exposed to ultravioletradiation. Examples of such oxides include, without limitation oxidesof: Ti, V, Cr, Mn, Fe, Co, Ni, Cu, Ce, W, and Mo.

In one or more embodiments, the glass composition includes Fe expressedas Fe₂O₃, wherein Fe is present in an amount up to (and including) about1 mol %. In some embodiments, the glass composition is substantiallyfree of Fe. In one or more embodiments, the glass composition comprisesFe₂O₃ in an amount equal to or less than about 0.2 mol %, less thanabout 0.18 mol %, less than about 0.16 mol %, less than about 0.15 mol%, less than about 0.14 mol %, less than about 0.12 mol %. In one ormore embodiments, the glass composition comprises Fe₂O₃ in a range fromabout 0.01 mol % to about 0.2 mol %, from about 0.01 mol % to about 0.18mol %, from about 0.01 mol % to about 0.16 mol %, from about 0.01 mol %to about 0.15 mol %, from about 0.01 mol % to about 0.14 mol %, fromabout 0.01 mol % to about 0.12 mol %, or from about 0.01 mol % to about0.10 mol %, and all ranges and sub-ranges therebetween.

Where the glass composition includes TiO₂, TiO₂ may be present in anamount of about 5 mol % or less, about 2.5 mol % or less, about 2 mol %or less or about 1 mol % or less. In one or more embodiments, the glasscomposition may be substantially free of TiO₂.

An exemplary glass composition includes SiO₂ in an amount in a rangefrom about 65 mol % to about 75 mol %, Al₂O₃ in an amount in a rangefrom about 8 mol % to about 14 mol %, Na₂O in an amount in a range fromabout 12 mol % to about 17 mol %, K₂O in an amount in a range of about 0mol % to about 0.2 mol %, and MgO in an amount in a range from about 1.5mol % to about 6 mol %. Optionally, SnO₂ may be included in the amountsotherwise disclosed herein.

In one or more embodiments, the cold-bent glass substrate 140 has acurvature (first radius of curvature) that matches the curvature (secondradius of curvature) of at least a portion of the display module 150 (ormatches the radius of curvature of the curved surface of the base of thevehicle interior system). In one or more embodiments, at least a portionof the display module 150 is curved to approach or match the curvatureof the cold-bent glass substrate 140. In one or more embodiments, thedisplay module 150 includes a second glass substrate, a backlight unitand other components, any of which may be flexible or may permanentlyexhibit a curvature. In some embodiments, the entire display module iscurved to a second radius of curvature. In one or more embodiments, theglass substrate 140 is cold-bent to a curvature that approaches ormatches the curvature of at least a portion of the display module 150.In one or more embodiments, at least a portion of the display module 150is cold-bent to a curvature that approaches or matches the curvature ofthe cold-bent glass substrate 140.

In one or more embodiments, when the first radius of curvature of theglass substrate varies across its area, the first radius of curvaturereferred to herein is the minimum radius of curvature of the glasssubstrate. Similarly, in one or more embodiments, when the second radiusof curvature of the display module varies across its area, the secondradius of curvature referred to herein is the minimum radius ofcurvature of the display module. In one or more embodiments, the firstradius of curvature may be the minimum radius of curvature adjacent tothe display module (as described herein) or the touch panel. In one ormore embodiment, the location of the first radius of curvature is thesame or near the location of the second radius of curvature. In otherwords, the first radius of curvature of the curved glass substrate ismeasured at the same or near the same location at which the secondradius of curvature is measured on the second glass substrate or thecurved surface of the base in terms of width and length. In one or moreembodiments, the term “near” when used with reference to the first andsecond radius of curvature means the first radius of curvature and thesecond radius of curvature are measured at locations within a distanceof 10 cm, 5 cm, or 2 cm from one another.

In one or more embodiments, the glass substrate 140 has a first radiusof curvature of about 20 mm or greater, 40 mm or greater, 50 mm orgreater, 60 mm or greater, 100 mm or greater, 250 mm or greater or 500mm or greater. For example, the first radius of curvature may be in arange from about 20 mm to about 1500 mm, from about 30 mm to about 1500mm, from about 40 mm to about 1500 mm, from about 50 mm to about 1500mm, 60 mm to about 1500 mm, from about 70 mm to about 1500 mm, fromabout 80 mm to about 1500 mm, from about 90 mm to about 1500 mm, fromabout 100 mm to about 1500 mm, from about 120 mm to about 1500 mm, fromabout 140 mm to about 1500 mm, from about 150 mm to about 1500 mm, fromabout 160 mm to about 1500 mm, from about 180 mm to about 1500 mm, fromabout 200 mm to about 1500 mm, from about 220 mm to about 1500 mm, fromabout 240 mm to about 1500 mm, from about 250 mm to about 1500 mm, fromabout 260 mm to about 1500 mm, from about 270 mm to about 1500 mm, fromabout 280 mm to about 1500 mm, from about 290 mm to about 1500 mm, fromabout 300 mm to about 1500 mm, from about 350 mm to about 1500 mm, fromabout 400 mm to about 1500 mm, from about 450 mm to about 1500 mm, fromabout 500 mm to about 1500 mm, from about 550 mm to about 1500 mm, fromabout 600 mm to about 1500 mm, from about 650 mm to about 1500 mm, fromabout 700 mm to about 1500 mm, from about 750 mm to about 1500 mm, fromabout 800 mm to about 1500 mm, from about 900 mm to about 1500 mm, fromabout 950 mm to about 1500 mm, from about 1000 mm to about 1500 mm, fromabout 1250 mm to about 1500 mm, from about 20 mm to about 1400 mm, fromabout 20 mm to about 1300 mm, from about 20 mm to about 1200 mm, fromabout 20 mm to about 1100 mm, from about 20 mm to about 1000 mm, fromabout 20 mm to about 950 mm, from about 20 mm to about 900 mm, fromabout 20 mm to about 850 mm, from about 20 mm to about 800 mm, fromabout 20 mm to about 750 mm, from about 20 mm to about 700 mm, fromabout 20 mm to about 650 mm, from about 20 mm to about 200 mm, fromabout 20 mm to about 550 mm, from about 20 mm to about 500 mm, fromabout 20 mm to about 450 mm, from about 20 mm to about 400 mm, fromabout 20 mm to about 350 mm, from about 20 mm to about 300 mm, fromabout 20 mm to about 250 mm, from about 20 mm to about 200 mm, fromabout 20 mm to about 150 mm, from about 20 mm to about 100 mm, fromabout 20 mm to about 50 mm, from about 60 mm to about 1400 mm, fromabout 60 mm to about 1300 mm, from about 60 mm to about 1200 mm, fromabout 60 mm to about 1100 mm, from about 60 mm to about 1000 mm, fromabout 60 mm to about 950 mm, from about 60 mm to about 900 mm, fromabout 60 mm to about 850 mm, from about 60 mm to about 800 mm, fromabout 60 mm to about 750 mm, from about 60 mm to about 700 mm, fromabout 60 mm to about 650 mm, from about 60 mm to about 600 mm, fromabout 60 mm to about 550 mm, from about 60 mm to about 500 mm, fromabout 60 mm to about 450 mm, from about 60 mm to about 400 mm, fromabout 60 mm to about 350 mm, from about 60 mm to about 300 mm, or fromabout 60 mm to about 250 mm. In one or more embodiments, glasssubstrates having a thickness of less than about 0.4 mm may exhibit aradius of curvature that is less than about 100 mm, or less than about60 mm.

In one or more embodiments, the display module 150 (or the curvedsurface of the base of the vehicle interior system) has a second radiusof curvature of about 20 mm or greater, 40 mm or greater, 50 mm orgreater, 60 mm or greater, 100 mm or greater, 250 mm or greater or 500mm or greater. For example, the second radius of curvature may be in arange from about 20 mm to about 1500 mm, from about 30 mm to about 1500mm, from about 40 mm to about 1500 mm, from about 50 mm to about 1500mm, 60 mm to about 1500 mm, from about 70 mm to about 1500 mm, fromabout 80 mm to about 1500 mm, from about 90 mm to about 1500 mm, fromabout 100 mm to about 1500 mm, from about 120 mm to about 1500 mm, fromabout 140 mm to about 1500 mm, from about 150 mm to about 1500 mm, fromabout 160 mm to about 1500 mm, from about 180 mm to about 1500 mm, fromabout 200 mm to about 1500 mm, from about 220 mm to about 1500 mm, fromabout 240 mm to about 1500 mm, from about 250 mm to about 1500 mm, fromabout 260 mm to about 1500 mm, from about 270 mm to about 1500 mm, fromabout 280 mm to about 1500 mm, from about 290 mm to about 1500 mm, fromabout 300 mm to about 1500 mm, from about 350 mm to about 1500 mm, fromabout 400 mm to about 1500 mm, from about 450 mm to about 1500 mm, fromabout 500 mm to about 1500 mm, from about 550 mm to about 1500 mm, fromabout 600 mm to about 1500 mm, from about 650 mm to about 1500 mm, fromabout 700 mm to about 1500 mm, from about 750 mm to about 1500 mm, fromabout 800 mm to about 1500 mm, from about 900 mm to about 1500 mm, fromabout 950 mm to about 1500 mm, from about 1000 mm to about 1500 mm, fromabout 1250 mm to about 1500 mm, from about 20 mm to about 1400 mm, fromabout 20 mm to about 1300 mm, from about 20 mm to about 1200 mm, fromabout 20 mm to about 1100 mm, from about 20 mm to about 1000 mm, fromabout 20 mm to about 950 mm, from about 20 mm to about 900 mm, fromabout 20 mm to about 850 mm, from about 20 mm to about 800 mm, fromabout 20 mm to about 750 mm, from about 20 mm to about 700 mm, fromabout 20 mm to about 650 mm, from about 20 mm to about 200 mm, fromabout 20 mm to about 550 mm, from about 20 mm to about 500 mm, fromabout 20 mm to about 450 mm, from about 20 mm to about 400 mm, fromabout 20 mm to about 350 mm, from about 20 mm to about 300 mm, fromabout 20 mm to about 250 mm, from about 20 mm to about 200 mm, fromabout 20 mm to about 150 mm, from about 20 mm to about 100 mm, fromabout 20 mm to about 50 mm, from about 60 mm to about 1400 mm, fromabout 60 mm to about 1300 mm, from about 60 mm to about 1200 mm, fromabout 60 mm to about 1100 mm, from about 60 mm to about 1000 mm, fromabout 60 mm to about 950 mm, from about 60 mm to about 900 mm, fromabout 60 mm to about 850 mm, from about 60 mm to about 800 mm, fromabout 60 mm to about 750 mm, from about 60 mm to about 700 mm, fromabout 60 mm to about 650 mm, from about 60 mm to about 600 mm, fromabout 60 mm to about 550 mm, from about 60 mm to about 500 mm, fromabout 60 mm to about 450 mm, from about 60 mm to about 400 mm, fromabout 60 mm to about 350 mm, from about 60 mm to about 300 mm, or fromabout 60 mm to about 250 mm. In one or more embodiments, glasssubstrates having a thickness of less than about 0.4 mm may exhibit aradius of curvature that is less than about 100 mm, or less than about60 mm.

In one or more embodiments, the glass substrate is cold-bent to exhibita first radius curvature that is within 10% (e.g., about 10% or less,about 9% or less, about 8% or less, about 7% or less, about 6% or less,or about 5% or less) of the second radius of curvature of the displaymodule 150 (or the curved surface of the base of the vehicle interiorsystem). For example, if the display module 150 (or the curved surfaceof the base of the vehicle interior system) exhibits a radius ofcurvature of 1000 mmm, the glass substrate is cold-bent to have a radiusof curvature in a range from about 900 mm to about 1100 mm.

In one or more embodiments, the display module 150 as shown in FIG. 5and includes a second glass substrate 152 and a backlight unit 154. Asshown in FIG. 6 and FIG. 7, the second glass substrate is disposedadjacent the first major surface 142 of the glass substrate.Accordingly, the second glass substrate 152 is disposed between thebacklight unit 154 and the first major surface 142. In the embodimentshown, the backlight unit 154 is optionally curved to exhibit the secondradius of curvature of the display module 150. In one or moreembodiments, the backlight unit 154 may be flexible to curve to thesecond radius of curvature. In one or more embodiments, the second glasssubstrate 152 may be curved to the second radius of curvature. In one ormore specific embodiments, the second glass substrate may be cold-bentto exhibit the second radius of curvature. In such embodiments, thesecond radius of curvature is measured on the surface of the secondglass substrate 152 adjacent the glass substrate 140. In one or moreembodiments, the display module 150 (including any one or more of thebacklight unit, the second glass substrate, and the frame) arepermanently curved to the second radius of curvature of the displaymodule 150. In one or more embodiments, the second glass substrate maybe cold-bent before or during lamination. The backlight unit may beattached to the curved glass substrate, the second glass substrateand/or the frame (as described herein) via an adhesive (as describedherein) or by mechanical means (e.g., screws, clamps, clips and thelike) known in the art.

In one or more embodiments, the second glass substrate may have athickness greater than the thickness of the glass substrate. In one ormore embodiments, the thickness is greater than 1 mm, or about 1.5 mm orgreater. In one or more embodiments, the thickness of the second glasssubstrate may have a thickness that is substantially the same as theglass substrate. In one or more embodiments, the second glass substratehas a thickness in a range from about 0.1 mm to about 1.5 mm, from about0.15 mm to about 1.5 mm, from about 0.2 mm to about 1.5 mm, from about0.25 mm to about 1.5 mm, from about 0.3 mm to about 1.5 mm, from about0.35 mm to about 1.5 mm, from about 0.4 mm to about 1.5 mm, from about0.45 mm to about 1.5 mm, from about 0.5 mm to about 1.5 mm, from about0.55 mm to about 1.5 mm, from about 0.6 mm to about 1.5 mm, from about0.65 mm to about 1.5 mm, from about 0.7 mm to about 1.5 mm, from about0.1 mm to about 1.4 mm, from about 0.1 mm to about 1.3 mm, from about0.1 mm to about 1.2 mm, from about 0.1 mm to about 1.1 mm, from about0.1 mm to about 1.05 mm, from about 0.1 mm to about 1 mm, from about 0.1mm to about 0.95 mm, from about 0.1 mm to about 0.9 mm, from about 0.1mm to about 0.85 mm, from about 0.1 mm to about 0.8 mm, from about 0.1mm to about 0.75 mm, from about 0.1 mm to about 0.7 mm, from about 0.1mm to about 0.65 mm, from about 0.1 mm to about 0.6 mm, from about 0.1mm to about 0.55 mm, from about 0.1 mm to about 0.5 mm, from about 0.1mm to about 0.4 mm, or from about 0.3 mm to about 0.7 mm.

The second glass substrate may have the same glass composition as theglass substrate 140 or may differ from the glass composition used forthe glass substrate 140. In one or more embodiments, the second glasssubstrate may have an alkali-free glass composition. Suitable glasscompositions for use in the second glass substrate may include soda limeglass, alkali-free aluminosilicate glass, alkali-free borosilicateglass, alkali-free boroaluminosilicate glass, alkali-containingaluminosilicate glass, alkali-containing borosilicate glass, andalkali-containing boroaluminosilicate glass. In one or more embodiments,the second glass substrate may be strengthened (as disclosed herein withrespect to the glass substrate 140). In some embodiments, the secondglass substrate is unstrengthened or strengthened only by mechanicaland/or thermal strengthening (i.e., not strengthened by chemicalstrengthening). In some embodiments, the second glass substrate may beannealed.

In one or more embodiments, the display comprises an organiclight-emitting diode (OLED) display. In such embodiments, the firstradius of curvature of the glass substrate is within 10% of the secondradius of curvature of the OLED display or the curved surface on whichit is assembled (such as the base).

In one or more embodiments, the display module 150 includes a frame 158.In the embodiment shown, the frame 158 is positioned between thebacklight unit 154 and the second glass substrate 152. The frame mayinclude flanges 159 extending outward from the display module 150forming an “L” shape with respect to the frame. In one or moreembodiments, the frame 158 at least partially surrounds the backlightunit 154. In one or more embodiments as shown in FIG. 6, the frame atleast partially surrounds the second glass substrate 152. In one or moreembodiments in which the display module comprises an OLED display, theOLED structure is between the frame and the glass substrate.

In one or more embodiments, the frame 158 is associated or assembledwith the glass substrate 140, the second glass substrate 152 or anothercomponent of the display module in the case of OLED displays. In one ormore embodiments, the frame can either at least partially surrounds theminor surface 146 of the glass substrate 140 or the minor surface of theglass substrate may not be surrounded by the frame. In other words, theframe may include secondary flanges 157 that extend to partiallysurround the second glass substrate 152, the minor surface of the glasssubstrate 140, and/or another component of the display module in thecase of OLED displays.

In one or more embodiments, the frame 158 includes one or more snap-infeatures or other features that enable easy and quick installation ofthe display module 150 in the vehicle interiors. Specifically, thesnap-in features or other similar features can be used to assemble thedisplay module with a center console base 110 with a curved surface 120,a dashboard base 210 with a curved surface 220 or a steering wheel base310 with a curved surface 320. In one or more embodiments, the snap-infeatures could be added separately on the frame or may be integral tothe frame. The snap-in features could include various snap-in jointssuch as cantilever, torsion, annular, and the like that engage with acorresponding component after assembly. Such snap-in joints can includea first component including a protruding part (such as hook, stud, etc.)that is deflected briefly during the joining process with the vehicleinterior and mates with a second component including an opening ordepression disposed on the vehicle interior system. After theinstallation process, the protruding part returns to a stress-freestate.

An exemplary frame 158 is shown in FIG. 20A. In FIG. 20A, the frame 158includes a first component 156 in the form of a protruding part(specifically a cantilever snap-fit joint) and a center console base 110with a curved surface 120 that includes a second portion 122, in theform of an opening 123, that mates with the first component. In FIGS.20B and 20C, the display module 150 includes the frame 158 with thefirst component 156 and the center console base 110 with the curvedsurface 120 and second portion 122 before assembly. FIG. 20D shows thedisplay module 150 and center console base 110 after assembly. Suchembodiments of the frame that permit ease of assembly without the use ofadditional parts and reduce the time for assembly and related processcost. The frame may be fabricated using an injection molding process inwhich the first component (and the snap-in features) is incorporated inthe die. In one or more embodiments, the frame may be used to enable anafter-market display module that can be assembled to various vehicleinteriors.

In one or more embodiments, the display includes an adhesive or adhesivelayer 160 between the glass substrate 140 and the display module 150.The adhesive may be optically clear. In some embodiments, the adhesiveis disposed on a portion of the glass substrate 140 and/or the displaymodule 150. For example, as shown in FIG. 4, the glass substrate mayinclude a periphery 147 adjacent the minor surface 146 defining aninterior portion 148 and the adhesive may be disposed on at least aportion of the periphery. The thickness of the adhesive may be tailoredto ensure lamination between the display module 150 (and moreparticularly the second glass substrate) and the glass substrate 140.For example, the adhesive may have a thickness of about 1 mm or less. Insome embodiments, the adhesive has a thickness in a range from about 200μm to about 500 μm, from about 225 μm to about 500 μm, from about 250 μmto about 500 μm, from about 275 μm to about 500 μm, from about 300 μm toabout 500 μm, from about 325 μm to about 500 μm, from about 350 μm toabout 500 μm, from about 375 μm to about 500 μm, from about 400 μm toabout 500 μm, from about 200 μm to about 475 μm, from about 200 μm toabout 450 μm, from about 200 μm to about 425 μm, from about 200 μm toabout 400 μm, from about 200 μm to about 375 μm, from about 200 μm toabout 350 μm, from about 200 μm to about 325 μm, from about 200 μm toabout 300 μm, or from about 225 μm to about 275 μm.

In one or more embodiments, the either one of or both the first majorsurface 142 and the second major surface 144 of the glass substrateincludes a surface treatment. The surface treatment may cover at least aportion of the first major surface 142 and the second major surface 144.Exemplary surface treatments include an easy-to-clean surface, ananti-glare surface, an anti-reflective surface, a haptic surface, and adecorative surface. In one or more embodiments, the at least a portionof the first major surface and 142/or the second major surface 144 mayinclude any one, any two or all three of an anti-glare surface, ananti-reflective surface, a haptic surface, and a decorative surface. Forexample, first major surface 142 may include an anti-glare surface andthe second major surface 144 may include an anti-reflective surface. Inanother example, the first major surface 142 includes an anti-reflectivesurface and the second major surface 144 includes an anti-glare surface.In yet another example, the first major surface 142 comprises either oneof or both the anti-glare surface and the anti-reflective surface, andthe second major surface 144 includes the decorative surface.

The anti-reflective surface may be formed using an etching process andmay exhibit a transmission haze 20% or less (e.g., about 15% or less, orabout 10% or less), and a distinctiveness of image (DOI) of about 80 orless. As used herein, the terms “transmission haze” and “haze” refer tothe percentage of transmitted light scattered outside an angular cone ofabout ±2.5° in accordance with ASTM procedure D1003. For an opticallysmooth surface, transmission haze is generally near zero. As usedherein, the term “distinctness of image” is defined by method A of ASTMprocedure D5767 (ASTM 5767), entitled “Standard Test Methods forInstrumental Measurements of Distinctness-of-Image Gloss of CoatingSurfaces,” the contents of which are incorporated herein by reference intheir entirety. In accordance with method A of ASTM 5767, substratereflectance factor measurements are made on the anti-glare surface atthe specular viewing angle and at an angle slightly off the specularviewing angle. The values obtained from these measurements are combinedto provide a DOI value. In particular, DOI is calculated according tothe equation

$\begin{matrix}{{{D\; O\; I} = {\left\lbrack {1 - \frac{Ros}{Rs}} \right\rbrack \times 100}},} & (1)\end{matrix}$where Ros is the relative reflection intensity average between 0.2° and0.4 away from the specular reflection direction, and Rs is the relativereflection intensity average in the specular direction (between +0.05°and −0.05°, centered around the specular reflection direction). If theinput light source angle is +20° from the sample surface normal (as itis throughout this disclosure), and the surface normal to the sample istaken as 0°, then the measurement of specular reflected light Rs istaken as an average in the range of about −19.95° to −20.05°, and Ros istaken as the average reflected intensity in the range of about −20.2° to−20.4° (or from −19.6° to −19.8°, or an average of both of these tworanges). As used herein, DOI values should be directly interpreted asspecifying a target ratio of Ros/Rs as defined herein. In someembodiments, the anti-glare surface has a reflected scattering profilesuch that >95% of the reflected optical power is contained within a coneof +/−10°, where the cone is centered around the specular reflectiondirection for any input angle.

The resulting the anti-glare surface may include a textured surface withplurality of concave features having an opening facing outwardly fromthe surface. The opening may have an average cross-sectional dimensionof about 30 micrometers or less. In one or more embodiments, theanti-glare surface exhibits low sparkle (in terms of low pixel powerdeviation reference or PPDr) such as PPDr of about 6% or less, As usedherein, the terms “pixel power deviation referenced” and “PPDr” refer tothe quantitative measurement for display sparkle. Unless otherwisespecified, PPDr is measured using a display arrangement that includes anedge-lit liquid crystal display screen (twisted nematic liquid crystaldisplay) having a native sub-pixel pitch of 60 μm×180 μm and a sub-pixelopening window size of about 44 μm×about 142 μm. The front surface ofthe liquid crystal display screen had a glossy, anti-reflection typelinear polarizer film. To determine PPDr of a display system or ananti-glare surface that forms a portion of a display system, a screen isplaced in the focal region of an “eye-simulator” camera, whichapproximates the parameters of the eye of a human observer. As such, thecamera system includes an aperture (or “pupil aperture”) that isinserted into the optical path to adjust the collection angle of light,and thus approximate the aperture of the pupil of the human eye. In thePPDr measurements described herein, the iris diaphragm subtends an angleof 18 milliradians.

The anti-reflective surface may be formed by a multi-layer coating stackformed from alternating layers of a high refractive index material and alow refractive index material. Such coatings stacks may include 6 layersor more. In one or more embodiment, the anti-reflective surface mayexhibit a single-side average light reflectance of about 2% or less(e.g., about 1.5% or less, about 1% or less, about 0.75% or less, about0.5% or less, or about 0.25% or less) over the optical wavelength regimein the range from about 400 nm to about 800 nm. The average reflectanceis measured at an incident illumination angle greater than about 0degrees to less than about 10 degrees.

The decorative surface may include any aesthetic design formed from apigment (e.g., ink, paint and the like) and can include a wood-graindesign, a brushed metal design, a graphic design, a portrait, or a logo.In one or more embodiments, the decorative surface exhibits a deadfronteffect in which the decorative surface disguises or masks the underlyingdisplay from a viewer when the display is turned off but permits thedisplay to be viewed when the display is turned on. The decorativesurface may be printed onto the glass substrate. In one or moreembodiments, the anti-glare surface includes an etched surface. In oneor more embodiments, the anti-reflective surface includes a multi-layercoating. In one or more embodiments, the easy-to-clean surface includesan oleophobic coating that imparts anti-fingerprint properties. In oneor more embodiments, the haptic surface includes a raised or recessedsurface formed from depositing a polymer or glass material on thesurface to provide a user with tactile feedback when touched.

In one or more embodiments, the surface treatment (i.e., theeasy-to-clean surface, the anti-glare surface, the anti-reflectivesurface, the haptic surface and/or the decorative surface) is disposedon at least a portion of the periphery 147 and the interior portion 148is substantially free of the surface treatment.

In one or more embodiments, the display module includes touchfunctionality and such functionality is accessible through the glasssubstrate 140. In one or more embodiments, displayed images or contentshown by the display module is visible through the glass substrate 140.

A second aspect of this disclosure pertains to various methods andsystems for cold-bending a glass substrate, such as substrate 140,and/or forming a display. In various embodiments, the methods andsystems discussed herein utilize air pressure differentials to causebending of the glass substrate. As noted above, these systems andmethods bend the glass substrate without use of the high temperatures(e.g., temperatures greater than the glass softening point) that aretypical with hot-bending/hot-forming processes.

Referring to FIGS. 8 and 9, a method 1000 of forming a display is shownaccording to exemplary embodiments. In one or more embodiments, themethod includes a step 1100 of cold-bending a glass substrate, such assubstrate 140, to a first radius of curvature (as described herein), andlaminating a display module 150 to the first one of the major surfaces142 or 144 (see FIGS. 2 and 3) while maintaining the first radius ofcurvature in the glass substrate to form the display. In one or moreembodiments, the display module has a second radius of curvature (asdescribed herein) that is within 10% of the first radius of curvature.As shown in FIG. 9, in one or more embodiments, cold-bending the glasssubstrate 140 includes applying a vacuum to the second major surface 144of the glass substrate to generate the first radius of curvature 1120.Accordingly, in the embodiment shown in FIG. 9, applying the vacuumincludes placing the glass substrate on a vacuum fixture 1110 beforeapplying the vacuum to the second major surface. In one or moreembodiments, to maintain the first radius of curvature, the glasssubstrate and subsequent assembly with the display module (steps 1150,1200) is performed while the vacuum is applied to the glass substrate tocold-bend the glass substrate to the first radius of curvature. In otherwords, the glass substrate 140 is temporarily cold-bent by applying thevacuum, and subsequent lamination with the display module 150permanently cold-bends the glass substrate and forms the display. Insuch embodiments, the display module provides the rigidity needed topermanently cold-bend the glass substrate. Other mechanisms totemporarily cold-bend the glass substrate may be used. For example, theglass substrate may be temporarily affixed to a mold having the desiredcurvature to cold-bend the glass substrate. The glass substrate may betemporarily affixed by a pressure sensitive adhesive or other mechanism.

After cold-bending the glass substrate, the method of one or moreembodiments includes laminating an adhesive to the first major surface142 of the glass substrate 140 before laminating the display module tothe first major surface such that the adhesive is disposed between thefirst major surface and the display module. In one or more embodiments,laminating the adhesive may include applying a layer of the adhesive andthen applying a normal force using roller or other mechanism. Exemplaryexamples include any suitable optically clear adhesive for bonding theglass substrate to the second glass substrate of the display module 150.In one example, the adhesive may include an optically clear adhesiveavailable from 3M Corporation under the trade name 8215. The thicknessof the adhesive may be in a range as otherwise described herein (e.g.,from about 200 μm to about 500 μm).

In one or more embodiment, step 1200 of laminating a display moduleincludes laminating the second glass substrate 152 to the glasssubstrate 140 (step 1210 in FIG. 9) and then attaching the backlightunit 154 to the second glass substrate (step 1220, in FIG. 9). In one ormore embodiments, the method includes cold-bending the second glasssubstrate during lamination to the glass substrate. In one or moreembodiments, the second glass substrate is curved prior to lamination.For example, the second glass substrate may be temporarily curved orcold-bent before lamination to exhibit the second radius of curvature.In another example, the second glass substrate may be permanently curved(by, for example, hot forming) to exhibit the second radius ofcurvature). In one or more embodiments, the backlight unit is curved toexhibit the second radius of curvature. In one or more embodiments, thebacklight unit is flexible and is curved during lamination to the secondradius of curvature. In one or more embodiments, the backlight unit maybe curved prior to lamination. For example, the backlight unit may betemporarily curved before lamination to exhibit the second radius ofcurvature. In another example, the backlight unit may be permanentlycurved to exhibit the second radius of curvature).

In one or more embodiments, step 1220 includes attaching a frame to oneof the backlight unit and the second glass substrate. In one or moreembodiments, the method includes step 1230 of removing the vacuum fromthe second major surface of glass substrate 140. For example, removingthe vacuum from the second major surface may include removing thedisplay from the vacuum fixture.

In one or more embodiments, the method includes disposing or assemblingthe display in a vehicle interior system 100, 200, 300. Where a frame isused, the frame may be used to assemble the display to a vehicleinterior system as otherwise described herein.

Referring to FIGS. 10-15, additional systems and methods for forming acurved glass substrate via cold-bending is shown and described. In thespecific embodiments shown and described, the curved glass substrate isutilized as a cover glass in vehicle interior system 100, 200, 300. Itshould be understood that any of the glass substrate, frame, and displaymodule embodiments described herein may be formed or utilized in theprocesses and systems discussed in relation to FIGS. 10-15.

Referring to FIG. 10, a method 1300 for cold-bending a glass substrateis shown. At step 1310, a glass substrate, such as glass substrate 140,is supported and/or placed on a curved frame. The frame may be a frameof a display, such as frame 158 (as described herein) that defines aperimeter and curved shape for a vehicle display. In general, the curvedframe includes a curved support surface and one of the major surfaces142 or 144 of glass substrate 140 is placed into contact with the curvedsupport surface of the frame.

At step 1320, an air pressure differential is applied to the glasssubstrate while it is supported by the frame causing the glass substrateto bend into conformity with the curved shape of the curved supportsurface of the frame. In this manner, a curved glass substrate is formedfrom a generally flat glass substrate (see FIGS. 3 and 4). In thisarrangement, curving the flat piece of glass material forms a curvedshape on the major surface facing the frame, while also causing acorresponding (but complimentary) curve to form in the major surface ofthe glass substrate opposite of the frame. Applicant has found that bybending the glass substrate directly on the curved frame, the need for aseparate curved die or mold (typically needed in other glass bendingprocesses) is eliminated. Further, Applicant has found that by shapingthe glass substrate directly to the curved frame, a wide range of glassradii may be achieved in a low complexity manufacturing process.

In some embodiments, the air pressure differential may be generated by avacuum fixture, such as fixture 1110. In some other embodiments, the airpressure differential is formed by applying a vacuum to an airtightenclosure surrounding the frame and the glass substrate. In specificembodiments, the airtight enclosure is a flexible polymer shell, such asa plastic bag or pouch. In other embodiments, the air pressuredifferential is formed by generating increased air pressure around theglass substrate and the frame with an overpressure device, such as anautoclave. Applicant has further found that air pressure provides aconsistent and highly uniform bending force (as compared to acontact-based bending method) which further leads to a robustmanufacturing process.

At step 1330, the temperature of the glass substrate is maintained belowthe glass softening point of the material of the glass substrate duringbending. As such, method 1300 is a cold-bending. In particularembodiments, the temperature of the glass substrate is maintained below500° C., 400° C., 300° C., 200° C. or 100° C. In a particularembodiment, the glass substrate is maintained at or below roomtemperature during bending. In a particular embodiment, the glasssubstrate is not actively heated via a heating element, furnace, oven,etc. during bending, as is the case when hot-forming glass to a curvedshape.

As noted above, in addition to providing processing advantages such aseliminating expensive and/or slow heating steps, the cold-bendingprocesses discussed herein are believed to generate curved glasssubstrates with a variety of properties that are superior to hot-formedglass substrates, particularly for display cover glass applications. Forexample, Applicant believes that, for at least some glass materials,heating during hot-forming processes decreases optical properties ofcurved glass substrates, and thus, the curved glass substrates formedutilizing the cold-bending processes/systems discussed herein providefor both curved glass shape along with improved optical qualities notbelieved achievable with hot-bending processes.

Further, many glass coating materials (e.g., anti-reflective coatings)are applied via deposition processes, such as sputtering processes thatare typically ill-suited for coating curved glass articles. In addition,many coating materials also are not able to survive the hightemperatures associated with hot-bending processes. Thus, in particularembodiments discussed herein, one or more coating material is applied tomajor surface 142 and/or to major surface 144 of glass substrate 140prior to cold-bending (when the glass substrate is flat), and the coatedglass substrate is bent to a curved shape as discussed herein. Thus,Applicant believes that the processes and systems discussed herein allowfor bending of glass after one or more coating material has been appliedto the glass, in contrast to typical hot-forming processes.

Referring to FIG. 11, a process 1400 for forming a display is shown. Atstep 1410 an adhesive material is applied between a curved supportsurface of the frame and first major surface 142 of glass substrate 140.In a particular embodiment, the adhesive is placed first onto the framesupport surface, and then at step 1420, glass substrate 140 is placedonto the adhesive coated frame. In another embodiment, the adhesive maybe placed onto first major surface 142 which is then placed into contactwith the support surface of the frame.

The adhesive material may be applied in a variety ways. In oneembodiment, the adhesive is applied using an applicator gun and mixingnozzle or premixed syringes, and spread uniformly using any of thefollowing, for example, a roller, a brush, a doctor blade or a draw downbar. In various embodiments, the adhesives discussed herein arestructural adhesives. In particular embodiments, the structuraladhesives may include, but not limited to, an adhesive selected from oneof more of the categories: (a) Toughened Epoxy (for example, MasterbondEP21TDCHT-LO, 3M Scotch Weld Epoxy DP460 Off-white); (b) Flexible Epoxy(for example, Masterbond EP21TDC-2LO, 3M Scotch Weld Epoxy 2216); (c)Acrylics and/or Toughened Acrylics (for example, LORD Adhesive 403, 406or 410 Acrylic adhesives with LORD Accelerator 19 or 19 GB w/LORD AP 134primer, LORD Adhesive 850 or 852/LORD Accelerator 25 GB, Loctite HF8000,Loctite AA4800); (d) Urethanes (for example, 3M Scotch Weld UrethaneDP640 Brown, Sikaflex 552 and Polyurethane (PUR) Hot Melt adhesives suchas, Technomelt PUR 9622-02 UVNA, Loctite HHD 3542, Loctite HHD 3580, 3MHotmelt adhesives 3764 and 3748); and (e) Silicones (Dow Corning 995,Dow Corning 3-0500 Silicone Assembly adhesive, Dow Corning 7091,SikaSil-GP). In some cases, structural adhesives available as sheets orfilms (for example, but not limited to, 3M Structural adhesive filmsAF126-2, AF 163-2M, SBT 9263 and 9214, Masterbond FLM36-LO) may beutilized. Furthermore, pressure sensitive structural adhesives such as3M VHB tapes may be utilized. In such embodiments, utilizing a pressuresensitive adhesive allows for the curved glass substrate to be bonded tothe frame without the need for a curing step.

At step 1420, a variety of different techniques or mechanisms can beutilized to align the glass substrate with the frame. For example, tabs,markings and clamps can be utilized to align the glass substrate withthe frame support surface.

At step 1430, an air pressure differential is applied to cause glasssubstrate 140 to bend into conformance with the shape of curved supportsurface of the curved frame, as discussed above regarding step 1320. Atstep 1440, the now curved glass substrate is bonded to the curved framesupport surface via the adhesive. Because the air pressure does notpermanently deform the glass substrate, the bonding step occurs duringapplication of the air pressure differential. In various embodiments,the air pressure differential is between 0.5 and 1.5 atmospheres ofpressure (atm), specifically between 0.7 and 1.1 atm, and morespecifically is 0.8 to 1 atm.

Performance of step 1440 is based upon the type of adhesive used tocreate the bond between the glass substrate and the frame. For example,in embodiments where increasing the temperature will accelerate the cureof the adhesive, heat is applied to cure the adhesive. In one suchembodiment, the heat-curable adhesive is cured by raising thetemperature to the cure temperature of the adhesive but lower than theglass softening point of the glass substrate, while the glass substrateis held bent in conformance with the shape of curved support surface ofthe curved frame via the pressure differential. In a specificembodiment, the heat may be applied using an oven or a furnace. Inanother embodiment, both heat and pressure may be applied via anoverpressure device, such as an autoclave.

In embodiments where the adhesive is a UV-curable adhesive, UV light isapplied to cure the adhesive. In other embodiments, the adhesive is apressure sensitive adhesive, pressure is applied to bond the adhesivebetween the glass substrate and the frame. In various embodiments,regardless of the process by which the bond between the glass substrateand the frame is formed, the adhesive may be an optically clearadhesive, such as a liquid optically clear adhesive.

At step 1450, a display module, such as display module 150, is attachedto the frame supporting the now curved and bonded glass substrate. Inspecific embodiments, the glass substrate-frame assembly may be removedfrom the device applying the pressure differential, prior to attachmentof the display module to the frame. In a specific embodiment, thedisplay module is attached to the frame via an adhesive such as anoptically clear adhesive. In other embodiments, the display module maybe attached to the frame by a variety of mechanical coupling devices,such as screws, snap-in or snap-fit components, etc. In a specificembodiment, a liquid optically clear adhesive (LOCA) available from E3Display at thickness of 125 μm is applied to bond the display module tothe frame and then the adhesive is UV cured to obtain the assembledpart.

FIG. 12 shows a graphical representation of process 1400 includingadditional steps according to an exemplary embodiment. At step 1425, theglass substrate supported on the frame is positioned within an airtightenclosure, shown as plastic vacuum bag 1426. In a specific embodiment, abreather cloth is placed on the frame 158/glass substrate 140 to provideconnectivity of the part surface to the vacuum port. Additionally, thebreather cloth helps in absorbing excess glue that may ooze out of thepart during the process.

Then at step 1430 a vacuum is drawn within vacuum bag 1426. At step1440, the vacuum bag 1426 with the glass substrate and frame arepositioned within an autoclave 1442 which generates heat to cure theadhesive bonding the glass substrate to the frame. In a specificembodiment, vacuum bag 1426 is placed in the autoclave at 66 degreesC./90 psi for 1 hour duration to cure the adhesive. At step 1460,following display module attachment at step 1450, an assembled displayassembly 1470 including the glass substrate (e.g., cover glass), displayframe, and display module is completed with all parts attached togetherand is ready for mounting in a vehicle interior.

Referring to FIG. 13, a process 1500 for forming a display is shownaccording to another embodiment. Process 1500 is substantially the sameas process 1400, except as discussed herein. Rather than attach thedisplay module to the frame following bending and following attachmentof the glass substrate to the frame, process 1500 attaches the displaymodule to the frame beforehand, at step 1510. In some such embodiments,the display module is bonded to frame via an adhesive that is curedduring the same cure step that bonds the glass substrate to the frame.In such embodiments, the display module is bonded to the frame duringapplication of the air pressure differential that causes the bending ofglass substrate to the frame.

Referring to FIGS. 14 and 15, display assembly 1470 is shown accordingto an exemplary embodiment. In the embodiment shown, the displayassembly includes frame 158 supporting both a display module 150 and acover glass substrate such as glass substrate 140. As shown in FIGS. 14and 15, both display module 150 and glass substrate 140 are coupled toframe 158, and display module 150 is positioned to allow a user to viewdisplay module 150 through glass substrate 140. In various embodiments,frame 158 may be formed from a variety of materials that include, butnot limited to plastics such as polycarbonate (PC), polypropylene (PP),Acrylonitrile-Butadiene-Styrene (ABS), PC/ABS blends, etc.), metals(Al-alloys, Mg-alloys, Fe-alloys, etc.), glass-filled resins, fiberreinforced plastics and fiber reinforced composites. Various processessuch as casting, machining, stamping, injection molding, extrusion,pultrusion, resin transfer molding etc. may be utilized to form thecurved shape of frame 158.

In another example, toughened epoxy adhesive (supplied by 3M under thetradename 3M Scotch Weld Epoxy DP460 Off-white) was applied to a majorsurface of a glass substrate or on a curved frame using an applicatorgun and mixing nozzle. A roller or brush was used to spread the adhesiveuniformly. The glass substrate and frame were stacked or assembled suchthat the adhesive layer is between the glass substrate and the frame. Ahigh temperature resistant tape was then applied to temporarily maintainthe stack alignment. The stack was then placed in a vacuum bag. In thisparticular example, a release cloth (optional) was placed over the stackto prevent sticking to the vacuum bag, and then a breather cloth wasplaced over to provide connectivity of the part surface to the vacuumport, and finally, the stack, release cloth and breather cloth assemblywas placed in a vacuum bag. The vacuum bag was then sealed to withstand760 mm of Hg. The vacuum bag was then deaired by drawing a vacuum duringwhich the glass substrate was bent to conform to the curved shape offrame support surface. The vacuum bag with the curved glass substrateand supporting frame were placed in an autoclave at 66° C./90 pounds persquare inch (psi) for 1 hour duration to cure the adhesive. The glasssubstrate is bonded to the curved frame support surface via the curedadhesive. The autoclave was then cooled down to a temperature below 45°C. before the pressure was released. The curved glass substrate/framestack was removed from the vacuum bag. The resulting curved glasssubstrate maintained the curved shape of the frame, with no delaminationvisible to the naked eye. A display module may be assembled to the stackto provide a display assembly

It should be understood that the adhesive may be applied and thecold-bent stack can be assembled with the curing of the adhesive eitherat room temperature or at elevated temperature or using UV depending onthe cure schedule of the particular adhesive. In some embodiments,pressure may be applied, along with heat. In some instances, heat aloneis applied to the stack. In one or more embodiments, heat may be appliedsuch that the temperature of the stack is in a range from greater thanroom temperature (i.e., 23° C.) up to 300° C., from about 25° C. toabout 300° C., from about 50° C. to about 300° C., from about 75° C. toabout 300° C., from about 100° C. to about 300° C., from about 110° C.to about 300° C., from about 115° C. to about 300° C., from about 120°C. to about 300° C., from about 150° C. to about 300° C., from about175° C. to about 300° C., from about 200° C. to about 300° C., fromabout 25° C. to about 250° C., from about 25° C. to about 200° C., fromabout 25° C. to about 150° C., from about 25° C. to about 125° C., fromabout 25° C. to about 115° C., from about 25° C. to about 110° C., orfrom about 25° C. to about 100° C. The stack may be heated to suchtemperatures for a duration from about 2 seconds to about 24 hours, 10seconds to about 24 hours, from about 30 seconds to about 24 hours, fromabout 1 minute to about 24 hours, from about 10 minutes to about 24hours, from about 15 minutes to about 24 hours, from about 20 minutes toabout 24 hours, from about 30 minutes to about 24 hours, from about 1hour to about 24 hours, from about 1.5 hours to about 24 hours, fromabout 2 hours to about 24 hours, from about 3 hours to about 24 hours,from about 2 seconds to about 4.5 hours, from about 2 seconds to about 4hours, from about 2 seconds to about 3 hours, from about 2 seconds toabout 2 hours, from about 2 seconds to about 1.5 hours, from about 2seconds to about 1 hour, from about 2 seconds to about 45 minutes, fromabout 2 seconds to about 30 minutes, from about 2 seconds to about 15minutes, from about 2 seconds to about 10 minutes, from about 10 minutesto about 45 minutes, or from about 15 minutes to about 45 minutes.

In various embodiments, the systems and methods described herein allowfor formation of glass substrate to conform to a wide variety of curvedshapes that frame 158 may have. As shown in FIG. 14, frame 158 has asupport surface 155 that has a curved shape to which glass substrate 140is shaped to match. In the specific embodiment shown in FIGS. 14 and 15,support surface 155 includes a convex section 161 and a concave section163, and glass substrate 140 is shaped to conform to the curved shapesof sections 161 and 163.

As will be generally understood, the opposing first and second majorsurfaces of glass substrate 140 both form curved shapes as glasssubstrate is bent to conform to the curved shape of frame supportsurface 155. Referring to FIG. 15, a first major surface 1471 of glasssubstrate 140 is the surface in contact with frame support surface 155,and during bending adopts the complementary shape of the frame supportsurface 155, while an outer, second major surface 1472 of glasssubstrate 140 adopts a curved shape that generally matches the curvedshape of the frame support surface 155. Thus, in this arrangement,second major surface 1472 has a convex section at the position of convexsection 161 of frame support surface 155 and has a concave section atthe position of concave section 163 of the frame support surface 155.Conversely, first major surface 1471 has a concave section at theposition of convex section 161 of the frame support surface 155 and hasa convex section at the position of concave section 163 of the framesupport surface 155.

In specific embodiments, the radius of curvature of convex curve 161 is250 mm, and the radius of concave curve 163 is 60 mm. In someembodiments, a non-curved central section is located between the twocurved sections. Further, in some embodiments, glass substrate 14 ischemically strengthened aluminosilicate glass with a thickness of 0.4mm.

It should be understood that FIGS. 14 and 15 provide a specific exampleof a glass substrate formed with more than one curved section, but invarious embodiments, the processes and systems discussed herein can beused to form a wide variety of curved substrates having more or lesscurved sections than shown in FIGS. 14 and 15. Further, it should beunderstood that while the exemplary embodiments discussed herein aredescribed primarily in relation to bending display cover glass, glasssubstrate 140 may be formed for any non-display curved glassapplication, such as cover glass for an instrument panel in a vehicle.

Referring to FIGS. 16A-16I, another aspect of this disclosure pertainsto kits and methods for assembling such kits to provide a display. FIGS.16A-16I show a cold-bent glass 2010 disposed between a viewer and thedisplay, where the glass substrate has a concave curvature from theviewer's point of view. In one or more embodiments, the curvature may beconvex, or may have a combination of convex and concave portions havingthe same or different radii from one another. Referring to FIGS.16A-16C, a kit 2000 according to one or more embodiments includes acold-bent glass substrate 2010 (as described herein according to one ormore embodiments) and a frame 2020. In one or more embodiments, thecold-bent glass substrate includes a first major surface 2012, a secondmajor surface 2014 opposing the first major surface and a minor surface2016 connecting the first major surface and the second major surface, athickness defined as a distance between the first major surface and thesecond major surface, a width defined as a first dimension of one of thefirst or second major surfaces orthogonal to the thickness, and a lengthdefined as a second dimension of one of the first or second majorsurfaces orthogonal to both the thickness and the width wherein thesecond major surface 2014 comprises a first radius of curvature. In theembodiments shown in FIGS. 16A-16F, the second major surface forms aconcave surface that exhibits a greater compressive stress than the samesurface exhibits prior to cold-bending. In some embodiments, the secondmajor surface exhibits a greater compressive stress than the first majorsurface. The frame 2020 has a curved surface 2022 that is coupled to thesecond major surface of the cold-bent glass substrate. The frame may becoupled to the glass substrate via an adhesive or mechanical means. Inone or more embodiments, the curved surface 2022 may have substantiallythe same radius of curvature as the first radius of curvature. In one ormore embodiments, the curved surface 2022 has the same radius ofcurvature as the first radius of curvature. The thickness of thecold-bent glass substrate is about 1.5 mm or less. In one or moreembodiments, the width of the cold-bent glass substrate is in a rangefrom about 5 cm to about 250 cm, and the length of the cold-bent glasssubstrate is from about 5 cm to about 250 cm. In one or moreembodiments, the first radius of curvature is 500 nm or greater. Theglass substrate may be strengthened as described herein.

In one or more embodiments, the kit includes a display module. As shownin the embodiment of FIG. 16B and FIG. 16C, the display module includesa display including a second glass substrate 2030, and an optionalbacklight unit 2040. In some embodiments, the display module includesonly a display (with no backlight unit 2040), as shown in FIG. 16E. Insuch embodiments, the backlight unit may be provided separately, andattached to the display, as shown in FIG. 16F. In one or moreembodiments, the display may be liquid crystal display or an OLEDdisplay. In one or more embodiments, the kit may include a touch panelinstead of the display module or in addition to the display module (withthe touch panel positioned to be disposed between the cold-bent glasssubstrate and the display module). In the embodiments shown in FIGS. 16Band 16C, the display or touch panel comprises a second glass substrate2030 that is curved. In such embodiments, the second glass substratecomprises a display surface or curved touch panel surface having asecond radius of curvature that is within 10% of the first radius ofcurvature. In embodiments in which an OLED display is used, the OLEDdisplay or the curved surface of the base has a second radius ofcurvature that is within 10% of the first radius of curvature. In someembodiments, such as shown in FIGS. 16C, 16E, 16F, 16H and 16I, the kitincludes an adhesive layer 2050 for attachment of the second glasssubstrate 2030 to the cold-bent glass substrate or the frame. Theadhesive layer may be disposed on the cold-bent glass substrate on thesurface thereof to be attached to the second glass substrate. In theembodiment shown in FIGS. 16A-16I, the adhesive layer is disposed on thefirst major surface). In one or more embodiments, the adhesive layer maybe disposed on the second glass substrate or both the cold-bent glasssubstrate and the second glass substrate. The adhesive 2050 may be anoptically clear adhesive, such as the optically clear adhesivesdescribed herein. In one or more embodiments, after the cold-bentsubstrate 2010 and the curved second glass substrate 2030 are laminated,it is believed that such lamination exerts lower stress on any adhesivelayer disposed therein. In one or more embodiments, the second radius ofcurvature may be within 5%, within 4%, within 3% or within 2% of thefirst radius of curvature. In some embodiments, the cold-bent glasssubstrate (and corresponding frame) and the second glass substrate aresubstantially aligned such that less than 2% of the width, less than 2%of the length or less than 2% of both the width and the length of thecold-bent glass is unaligned with the curved second glass substrate(i.e., unaligned portions are exposed), after lamination. In one or moreembodiments, less than 5% of the surface area of the first major surface2012 is unaligned with the second glass substrate or exposed afterlamination. In some embodiments, the thickness of the adhesive may beincreased to enhance alignment between the cold-bent glass substrate andthe second glass substrate.

As shown in FIG. 16C, 16E, 16F, 16H or 16I, the kit may include a secondglass substrate that is attached to the first major surface 2012. In oneor more embodiments, the second glass substrate is attached to the frame2020 (not shown). It should be understood that the frame 2020 may havethe features of the frame 158 described herein. A shown in theembodiments of FIGS. 16D and 16G, the second glass substrate 2030 issubstantially flat and is cold-bendable to a second radius of curvaturethat is within 10% of the first radius of curvature. As shown in FIGS.16D through 16F, the second glass substrate may be cold-bent to thesecond radius of curvature and attached to the cold-bent glass substrateor, optionally, the frame (not shown). In such embodiments, the secondglass substrate 2030 or the cold-bent glass substrate 2010 may comprisesan adhesive layer to attach the second glass substrate to the cold-bentglass substrate or the frame, as applicable. In one or more particularembodiments, the first major surface 2012 includes an adhesive disposedthereon. In such embodiments, the adhesive may be an optically clearadhesive that is a composite or exhibits different Young's modulusvalues on the surface in contact with or adjacent the first majorsurface, than the opposite surface that contacts or will contact thesecond glass substrate. It is believed that the second glass substratemay exert lower stress on the adhesive layer and thus a lower bendingforce may be required to cold-bend the second glass substrate to thecold-bent glass substrate. In some such embodiments, the cold-bent glasssubstrate and the second glass substrate are substantially aligned suchthat less than 2% of the width, less than 2% of the length or less than2% of both the width and the length of the cold-bent glass is unalignedwith the second glass substrate (i.e., unaligned portions are exposed),after lamination. In one or more embodiments, less than 5% of thesurface area of the first major surface 2012 is unaligned with thesecond glass substrate or exposed after lamination.

As shown in FIGS. 16B-16C and 16F, the backlight unit may be curved. Insome embodiments, the backlight unit exhibits a third radius ofcurvature that is within 10% of the first radius of curvature, within10% of the second radius of curvature, or within 10% of the first radiusof curvature and the second radius of curvature.

In the embodiments shown in FIGS. 16H-16I, the display comprises asecond glass substrate that is substantially flat and is attached to thefirst major surface. In such embodiments, the second glass substrate orthe cold-bent glass substrate comprises an adhesive layer 2050 thatattaches the second glass substrate to the cold-bent glass substrate(i.e., either directly to the first major surface or a portion of theframe). In such embodiments, the adhesive attaches a cold-bent glasssubstrate to a flat second glass substrate. A shown, in one or moreembodiments, the adhesive layer comprises a first surface that issubstantially flat and an opposing second surface having a second radiusof curvature that is within the 10% of the first radius of curvature. Insuch embodiments, the adhesive may be a liquid optically clear adhesive.In some embodiments, the first radius of curvature is in a range fromabout 500 nm to about 1000 nm.

In one or more embodiments, in the kit shown in FIGS. 16A-16I, an airgap may be present between the second glass substrate and the cold-bentglass substrate (i.e., the first major surface). In one or moreembodiments, the adhesive layer may be present on only a portion of thecold-bent glass substrate and/or the second glass substrate such thatthere is no attachment between a portion of the cold-bent glasssubstrate and the second glass substrate (as there is no adhesivepresent to form such attachment).

FIGS. 17A-17I illustrate various embodiments of a kit 3000 that includesa frame 3020 that is removable or is temporarily attached to a cold-bentglass substrate 3010. FIGS. 17A-17I show a convex curvature with thecold-bent glass 3010 disposed between a viewer and the display. In oneor more embodiments, the curvature may be concave, or may have acombination of convex and concave portions having the same or differentradii from one another. In one or more embodiments, the kit includes acold-bent glass substrate 3010 comprises a first major surface 3012, asecond major surface 3014 opposing the first major surface having afirst radius of curvature, and a minor surface connecting the firstmajor surface and the second major surface, a thickness defined as adistance between the first major surface and the second major surface, awidth defined as a first dimension of one of the first or second majorsurfaces orthogonal to the thickness, and a length defined as a seconddimension of one of the first or second major surfaces orthogonal toboth the thickness and the width, wherein the second major surfacecomprises a first radius of curvature, and a removable frame 3020removably coupled to the second major surface. It should be understoodthat the frame 3020 may have the features of the frame 158 describedherein. In one or more embodiments, the frame has a curved surface thatis coupled to the second major surface. The curved surface of the framemay have the same radius of curvature as the first radius of curvature.In the embodiments shown in FIGS. 17A-17I, the second major surfaceforms a concave surface that exhibits a greater compressive stress thanthe same surface exhibits prior to cold-bending. In some embodiments,the second major surface exhibits a greater compressive stress than thefirst major surface.

The thickness of the cold-bent glass substrate is about 1.5 mm or less.In one or more embodiments, the width of the cold-bent glass substrateis in a range from about 5 cm to about 250 cm, and the length of thecold-bent glass substrate is from about 5 cm to about 250 cm. In one ormore embodiments, the first radius of curvature is 500 nm or greater.The glass substrate may be strengthened as described herein.

In one or more embodiments shown in FIGS. 17A-17I, the kit includes adisplay module. As shown in FIG. 17B and FIG. 17C, the display moduleincludes a display including a second glass substrate 3030, and anoptional backlight unit 3040. In some embodiments, the display moduleincludes only a display (with no backlight unit 3040), as shown in FIG.17E. In such embodiments, the backlight unit or other mechanism orstructure may be provided separately, and attached as shown in FIG. 17Fto maintain the curved shape of the cold-bent glass substrate and thesecond glass substrate after the removable frame is removed. In one ormore embodiments, the display may be liquid crystal display or an OLEDdisplay. In one or more embodiments, the kit may include a touch panelinstead of the display module or in addition to the display module (withthe touch panel positioned to be disposed between the cold-bent glasssubstrate and the display module). In the embodiments shown in FIGS. 17Band 17C, the display or touch panel comprises a second glass substrate3030 that is curved. In such embodiments, the second glass substratecomprises a curved display surface or curved touch panel surface havinga second radius of curvature that is within 10% of the first radius ofcurvature. In one or more embodiments, the second glass substrate maycurved and have sufficient rigidity or structure to maintain thecold-bent shape of the cold-bent glass after the removable frame isremoved. In embodiments in which an OLED display is used, the OLEDdisplay or the curved surface of the base has a second radius ofcurvature that is within 10% of the first radius of curvature. In someembodiments, such as shown in FIGS. 17C, 17E, 17F, 17H and 17I, the kitcomprises an adhesive layer 3050 for attachment of the second glasssubstrate to the cold-bent glass substrate (and specifically, the firstmajor surface 3012). The adhesive layer may be provided on the cold-bentglass substrate (i.e., the first major surface), on the second glasssubstrate or both the cold-bent glass substrate and the second glasssubstrate. The adhesive 3050 may be an optically clear adhesive, such asthe optically clear adhesives described herein. In one or moreembodiments as shown in FIGS. 17B and 17C, after the curved cold-bentsubstrate 3010 and the curved second glass substrate 3030 are laminated,it is believed that such lamination exerts lower stress on any adhesivelayer disposed therein. In one or more embodiments, after the cold-bentsubstrate 3010 and the curved second glass substrate 3030 are laminated,the second radius of curvature may be within 5%, within 4%, within 3% orwithin 2% of the first radius of curvature. In some embodiments, thecold-bent glass substrate and the second glass substrate aresubstantially aligned such that less than 2% of the width, less than 2%of the length or less than 2% of both the width and the length of thecold-bent glass is unaligned with the second glass substrate (i.e.,unaligned portions are exposed), after lamination. In one or moreembodiments, less than 5% of the surface area of the first major surface2012 is unaligned with the second glass substrate or exposed afterlamination. In some embodiments, the thickness of the adhesive may beincreased to enhance alignment between the cold-bent glass substrate andthe second glass substrate.

As shown in FIG. 17C, 17E, 17F, 17H or 17I, the kit may include a secondglass substrate that is attached to the first major surface 3012. Ashown in FIGS. 17D and 17G, the second glass substrate 3030 may besubstantially flat and is cold-bendable to a second radius of curvaturethat is within 10% of the first radius of curvature. As shown in FIGS.17D through 17F, the second glass substrate may be cold-bent to thesecond radius of curvature and may be attached to the cold-bent glasssubstrate (i.e., the first major surface 3012). In such embodiments, thesecond glass substrate 3030 or the cold-bent glass substrate 3010 maycomprises an adhesive layer to attach the second glass substrate to thecold-bent glass substrate, as applicable. In one or more particularembodiments, the adhesive layer may be disposed on the first majorsurface. In such embodiments, the adhesive may be an optically clearadhesive that is a composite or exhibits different Young's modulusvalues on the surface in contact with or adjacent the first majorsurface, than the opposite surface that contacts or will contact thesecond glass substrate. It is believed that the second glass substratemay exert lower stress on the adhesive layer and thus a lower bendingforce is required to cold-bend the second glass substrate to thecold-bent glass substrate. In some such embodiments, the cold-bent glasssubstrate and the second glass substrate are substantially aligned suchthat less than 2% of the width, less than 2% of the length or less than2% of both the width and the length of the cold-bent glass is unalignedwith the second glass substrate (i.e., unaligned portions are exposed),after lamination. In one or more embodiments, less than 5% of thesurface area of the first major surface 2012 is unaligned with thesecond glass substrate or exposed after lamination.

As shown in FIGS. 17B-17C and 17F, a curved backlight unit 3040 may beattached to the second glass substrate 3030. In some embodiments, thebacklight unit 3040 exhibits a third radius of curvature that is within10% of the first radius of curvature, within 10% of the second radius ofcurvature, or within 10% of the first radius of curvature and the secondradius of curvature. In such embodiments, the backlight unit 3040provides the structure to maintain the curved shape of the cold-bentglass substrate and the second glass substrate, after the removableframe is removed, as shown in FIGS. 17C and 17F. Where a touch panel isincluded, a corresponding structure is attached to the second substrateopposite the surface that is attached or will attach to the cold-bentglass substrate.

In the embodiments shown in FIGS. 17H-17I, the display comprises asecond glass substrate 3030 that is substantially flat and is attachedto the first major surface. In such embodiments, the frame 3020maintains the curved shape of the cold-bent glass substrate, and thesecond glass substrate 3030 or the cold-bent glass substrate 3010comprises an adhesive layer 3050 that attaches the second glasssubstrate to the first major surface. In such embodiments, the adhesiveattaches a cold-bent glass substrate to a flat second glass substrate. Ashown, in one or more embodiments, the adhesive layer comprises a firstsurface that is substantially flat and an opposing second surface havinga second radius of curvature that is within the 10% of the first radiusof curvature. In such embodiments, the adhesive may be a liquidoptically clear adhesive. In some embodiments, the first radius ofcurvature is in a range from about 500 nm to about 1000 nm. In suchembodiments, the adhesive layer is a structural adhesive that providesthe structure to maintain the curved shape of the cold-bent glasssubstrate after the frame is removed, as shown in FIG. 17I.

In one or more embodiments, an air gap may be present between the secondglass substrate and the cold-bent glass substrate (i.e., the first majorsurface). In such embodiments, the adhesive layer may be present on onlya portion of the cold-bent glass substrate and/or the second glasssubstrate such that there is no attachment between a portion of thecold-bent glass substrate and the second glass substrate (as there is noadhesive present to form such attachment).

FIGS. 18A-18B illustrate a kit that includes a flexible glass substrate4010 that comprises a first major surface, a second major surfaceopposing the first major surface and a minor surface connecting thefirst major surface and the second major surface, a thickness defined asa distance between the first major surface and the second major surface,a width defined as a first dimension of one of the first or second majorsurfaces orthogonal to the thickness, and a length defined as a seconddimension of one of the first or second major surfaces orthogonal toboth the thickness and the width, and a curved display module 4020 or acurved touch panel having a first radius of curvature, as shown in FIG.18A. FIGS. 18A-18B show a convex curvature with the flexible glasssubstrate 4010 disposed between a viewer and the display. In one or moreembodiments, the curvature may be concave, or may have a combination ofconvex and concave portions having the same or different radii from oneanother.

The thickness of the flexible glass substrate 4010 is about 1.5 mm orless. In one or more embodiments, the width of the flexible glasssubstrate is in a range from about 5 cm to about 250 cm, and the lengthof the flexible glass substrate is from about 5 cm to about 250 cm. Inone or more embodiments, the first radius of curvature is 500 nm orgreater. In one or more embodiments, the flexible glass substrate may bestrengthened as described herein.

As shown in FIG. 18A and FIG. 18B, the display module includes a displayincluding a second glass substrate 4030, and a backlight unit 4040 orother structure for maintaining the curved shape of the curved displaymodule 4020. In some embodiments, the display module includes only adisplay (with no backlight unit 4040), as shown in FIG. 16E and FIG.18F. In such embodiments, the backlight unit or other structure may beprovided separately, and attached to the display, as shown in FIG. 18G.In one or more embodiments, the display may be liquid crystal display oran OLED display. In the embodiments shown in FIG. 18B, the displaycomprises a second glass substrate 4030 that is curved and exhibits thefirst radius of curvature. In one or more embodiments, the kit includesa curved touch panel instead of the curved display module or in additionto the curved display module (with the touch panel positioned to bedisposed between the cold-bent glass substrate and the curved displaymodule). In such embodiments, the curved touch panel includes a secondglass substrate that is curved, and which may optionally provide thestructural rigidity to maintain its curved shape (even after attachmentto the flexible glass substrate as shown in FIG. 18B). In someembodiments, the kit includes an adhesive layer 4050 for attachment ofthe second glass substrate 4030 to the flexible glass substrate 4010(i.e., the first major surface 4012). The adhesive layer may be providedon the flexible glass substrate (i.e., the first major surface), on thesecond glass substrate or both the flexible glass substrate and thesecond glass substrate. The adhesive 4050 may be an optically clearadhesive, such as the optically clear adhesives described herein. In oneor more embodiments, after the flexible glass substrate is cold-bent andlaminated to the curved display module or touch panel, the second majorsurface 4014 exhibits a second radius of curvature that is within 10%,within 5%, within 4%, within 3% or within 2% of the first radius ofcurvature. In embodiments in which an OLED display is used, the OLEDdisplay or the curved surface of the base has a second radius ofcurvature that is within 10% of the first radius of curvature. In theembodiments shown in FIG. 18B, the second major surface forms a concavesurface that exhibits a greater compressive stress than the same surfaceexhibits prior to cold-bending. In some embodiments, the second majorsurface exhibits a greater compressive stress than the first majorsurface.

In some embodiments, the resulting cold-bent glass substrate (andcorresponding frame) and the second glass substrate are substantiallyaligned such that less than 2% of the width, less than 2% of the lengthor less than 2% of both the width and the length of the cold-bent glassis unaligned with the second glass substrate (i.e., unaligned portionsare exposed), after lamination. In one or more embodiments, less than 5%of the surface area of the first major surface 2012 is unaligned withthe second glass substrate or exposed after lamination. In someembodiments, the thickness of the adhesive may be increased to enhancealignment between the cold-bent glass substrate and the second glasssubstrate.

In one or more embodiments, after the flexible glass substrate 4010 iscold-bent and laminated to the curved second glass substrate 4030, it isbelieved that the stress exerted on any adhesive layer disposed thereinmay be minimized by minimizing the thickness of the flexible glasssubstrate (i.e., to the ranges described herein). In one or moreembodiments, the kit includes a bezel formed on the flexible glasssubstrate to reduce stress on the flexible glass substrate whencold-bending.

As shown in FIG. 18B, the second glass substrate is attached to thefirst major surface 4012. A shown in FIG. 18A, the flexible glasssubstrate 4010 is substantially flat and is cold-bendable to a secondradius of curvature that is within 10% of the first radius of curvature.As shown in FIG. 18B, the flexible glass substrate is cold-bent to thesecond radius of curvature and attached to the second glass substrate.As shown in FIGS. 18A-18B, the backlight unit is curved and provides thestructure to maintain the cold-bent shape of the second glass substrateand the flexible glass substrate (after it is cold-bent to the secondglass substrate). In some embodiments, the backlight unit exhibits athird radius of curvature that is within 10% of the first radius ofcurvature, within 10% of the second radius of curvature, or within 10%of the first radius of curvature and the second radius of curvature. Insome embodiments, the second glass substrate is curved and can maintainthe curved shape of the cold-bent glass substrate with the backlightunit or other structure.

In one or more embodiments, an air gap may be present between the secondglass substrate and the cold-bent glass substrate (i.e., the first majorsurface). In such embodiments, the adhesive layer may be present on onlya portion of the cold-bent glass substrate and/or the second glasssubstrate such that there is no attachment between a portion of thecold-bent glass substrate and the second glass substrate (as there is noadhesive present to form such attachment).

FIGS. 19A-19E illustrate embodiments of a method of forming a display.FIGS. 19A-19E show a convex curvature; however, the curvature may beconcave, or may have a combination of convex and concave portions havingthe same or different radii from one another. In one or moreembodiments, the method 5000 includes cold-bending a stack 5001 to afirst radius of curvature as measured on a first surface 5005 of thestack. The stack may be a display stack, a touch panel stack or a stackthat includes a touch panel and display. In one or more embodiments, thedisplay may be liquid crystal display or an OLED display. The stack isshown in FIG. 19A and includes a first glass substrate 5010 having afirst major surface 5012 forming the first surface of the display stackand a second major surface 5014 opposite the first major surface, adisplay and/or touch panel module disposed on the second major surface5014. In the embodiment shown, the display and/or the touch panelinclude the second glass substrate 5030. In the embodiment shown in FIG.19A, the stack is placed on a frame 5020 prior to and duringcold-bending to maintain the cold-bent shape of the stack. It should beunderstood that the frame 5020 may have the features of the frame 158described herein. In one or more embodiments, the method includeslaminating the display and/or touch panel module to the second majorsurface such that second glass substrate (or other portion of thedisplay and/or touch panel) comprises a second radius of curvature thatis within 10% of the first radius of curvature. In one or moreembodiments, the first radius of curvature is in a range from about 20mm to about 1500 mm. In the embodiments shown in FIGS. 19A-19E, aftercold-bending, the second major surface forms a concave surface thatexhibits a greater compressive stress than the same surface exhibitsprior to cold-bending. In some embodiments, the second major surfaceexhibits a greater compressive stress than the first major surface. Inone or more embodiments, the method includes cold-bending the stack byapplying a vacuum to the first surface to generate the first radius ofcurvature. In one or more embodiments, applying the vacuum comprisesplacing the stack on a vacuum fixture before applying the vacuum to thefirst surface. In the embodiment shown in FIG. 19A, the method includesapplying an adhesive layer 5050 between the second glass substrate andthe first glass substrate before cold-bending the stack. In someembodiments, the adhesive layer is disposed on a portion of the secondglass substrate or the first glass substrate.

In the embodiment shown in FIG. 19A, the display module may include acold-bendable backlight unit 5040 disposed on the second glass substrateopposite the first glass substrate. In the embodiment shown in FIGS. 19Cthrough 19E, the module includes only a display or touch panel (with nobacklight unit 5040). In such embodiments, the backlight unit or othermechanism or structure may be provided separately, and attached to thedisplay or touch panel, as shown in FIG. 19E to maintain the curvedshape of the display stack. In some embodiments, the frame 5020 may beremoved if the backlight unit, second glass substrate, or othercomponent provides adequate structure to maintain the curved shape ofthe cold-bent glass substrate. In some embodiments, the frame and thebacklight unit cooperate together to maintain the cold-bent shape.Accordingly, in one or more embodiments, cold-bending and/or laminatinga display stack comprises attaching a backlight unit to the second glasssubstrate opposite the first glass substrate, wherein the backlight unitis optionally curved to exhibit the second radius of curvature.

In one or more embodiments, the method includes attaching a frame to thefirst glass substrate to maintain the first radius of curvature, andsimultaneously cold-bending and laminating the display stack.

In one or more embodiments, the first glass substrate is strengthened.In one or more embodiments, the second glass substrate isunstrengthened. In one or more embodiments, the second glass substratehas a thickness that is greater than a thickness of the glass substrate.In one or more embodiments, the method includes disposing the display ina vehicle interior system.

Example 1

Example 1 included a display formed from a 0.55 mm thick glass substratethat is chemically strengthened and exhibits a first radius of curvatureof about 1000 mm. The glass substrate was provided flat and one majorsurface (the second major surface) was placed on a vacuum chuck having aradius of curvature of 1000 mm. The vacuum was applied to the majorsurface of the glass substrate to temporarily cold—from the glasssubstrate to exhibit a first radius of curvature of about 1000 mm,matching the radius of curvature of the vacuum chuck. If the vacuum wasremoved, the glass substrate would return to being flat and would nolonger be cold-bent. While the glass substrate was disposed on thevacuum chuck and temporarily cold-bent, a layer of adhesive supplied by3M corporation under the tradename 8215 having a thickness of 250 μm isapplied to the first major surface of the glass substrate (i.e., thesurface that is exposed and not in contact with the vacuum chuck).Normal force was applied to a roller to laminate the adhesive to thefirst major surface of the cold-bent glass substrate. The adhesive layerincluded a carrier film, which was removed after the adhesive layer waslaminated to the cold-bent glass substrate.

A second glass substrate (which was a liquid crystal display glasssubstrate) was disposed on the adhesive layer. The second glasssubstrate was cold-bent and laminated to adhesive layer using a rollerand applying normal force. During lamination of the second glasssubstrate, the glass substrate continued to be temporarily cold-bentusing the vacuum. After lamination of the second glass substrate, abacklight and frame was applied to the second glass substrate. InExample 1, a double sided tape was applied between the frame and theglass substrate. The double sided tape was a double-sided acrylic foamtapes supplied by 3M Corporation under the trademark VHB™ Tapes. Theframe had an L-shaped bezel. The assembly of the frame and backlightunit completed formation of the display. The vacuum was then removedfrom the glass substrate and the display was removed. The cold-bentglass substrate was permanently cold-bent and had a first radius ofcurvature. The display module (and particularly the second glasssubstrate) exhibited a second radius of curvature that approached ormatched the first radius of curvature.

Aspect (1) pertains to a method of cold-bending a glass substratecomprising: supporting a glass substrate on a frame, wherein the glasssubstrate has a first major surface and a second major surface oppositethe first major surface, wherein the frame has a curved support surface,wherein the first major surface of the glass substrate faces the curvedsupport surface of the frame; and applying an air pressure differentialto the glass substrate while supported by the frame causing the glasssubstrate to bend such that the glass substrate conforms to the curvedshape of the curved support surface of the frame, forming a curved glasssubstrate, wherein the first major surface of the curved glass substrateincludes a curved section and the second major surface of the curvedglass substrate includes a curved section; wherein during application ofthe air pressure differential, a maximum temperature of the glasssubstrate is less than a glass softening point of the glass substrate.

Aspect (2) pertains to the method of Aspect (1), further comprising:applying an adhesive between the curved support surface of the frame andthe first major surface of the glass substrate; and bonding the firstmajor surface of the glass substrate to the support surface of the framewith the adhesive during application of the air pressure differential.

Aspect (3) pertains to the method of Aspect (2), wherein the adhesive isa heat-curable adhesive, wherein the bonding step comprises heating theglass substrate while supported by the frame to a temperature at orabove a cure temperature of the heat-curable adhesive and less than aglass softening point of the glass substrate.

Aspect (4) pertains to the method of any one of Aspects (1) through (3),wherein applying the air pressure differential comprises generating avacuum around the glass substrate and the frame.

Aspect (5) pertains to the method of Aspect (4), wherein the vacuum isgenerated by a vacuum fixture that supports the glass substrate on theframe.

Aspect (6) pertains to the method of Aspect (4), further comprisingsurrounding the glass substrate and the frame within an airtightenclosure, wherein the vacuum is applied to the airtight enclosure.

Aspect (7) pertains to the method of Aspect (6), wherein the airtightenclosure is a flexible polymer shell.

Aspect (8) pertains to the method of any one of Aspects (1) through (3),wherein applying the air pressure differential comprises increasing airpressure around the glass substrate and the frame.

Aspect (9) pertains to the method of Aspect (8), comprising surroundingthe glass substrate and the frame within an overpressure device, whereinthe air pressure is increased within the overpressure device.

Aspect (10) pertains to the method of any one of Aspects (1) through(9), wherein the curved support surface of the frame comprises a concavecurved section and/or a convex curved section, and wherein the glasssubstrate is bent such that the first major surface includes a concavecurved section and/or a convex curved section.

Aspect (11) pertains to the method of any one of Aspects (1) through(10), wherein the glass substrate is a strengthened piece of glassmaterial such that the first major surface is under a compressivestress, CS₁, and the second major surface is under a compressive stress,CS₂, wherein prior to bending CS₁ equals CS₂, and following bending CS₁is different than CS₂.

Aspect (12) pertains to the method of Aspect (11), wherein the curvedsection of the first major surface is a concave section and the curvedsection of the second major surface is a convex section, whereinfollowing bending, CS₁ is greater than CS₂.

Aspect (13) pertains to the method of Aspect (11) or Aspect (12),wherein the glass substrate is at least one of chemically strengthen andthermally strengthened.

Aspect (14) pertains to the method of any one of Aspects (1) through(13), wherein a maximum thickness of the glass substrate measuredbetween the first and second major surfaces is less than or equal to 1.5mm.

Aspect (15) pertains to the method of any one of Aspects (1) through(13), wherein a maximum thickness of the glass substrate measuredbetween the first and second major surfaces is 0.3 mm to 0.7 mm.

Aspect (16) pertains to the method of any one of Aspects (1) through(15), wherein the curved section of the first major surface is a concavesection and the curved section of the second major surface a convexsection, wherein the first major surface includes a second curvedsection having a convex shape, and the second major surface includes asecond curved section having a concave shape.

Aspect (17) pertains to the method of any one of Aspects (1) through(16), further comprising attaching a display module to the frame.

Aspect (18) pertains to the method of Aspect (17), wherein attaching thedisplay module comprises bonding the display module to the frame anadhesive during application of the air pressure differential.

Aspect (19) pertains to the method of Aspect (18), wherein the adhesivebonding of the display module to the frame is an optically clearadhesive.

Aspect (20) pertains to the method of any one of Aspects (1) through(19), wherein the temperature of the glass substrate is not raised abovethe glass softening point during or after bending, wherein the curvedglass substrate has an optical property that is superior to the opticalproperty of a glass substrate bent to a curved shape by heating to atemperature above the glass softening point.

Aspect (21) pertains to a vehicle interior system comprising: a basehaving a curved surface; a display disposed on the curved surface, thedisplay comprising a curved glass substrate comprises a first majorsurface, a second major surface opposing the first major surface and aminor surface connecting the first major surface and the second majorsurface, a thickness defined as a distance between the first majorsurface and the second major surface, a width defined as a firstdimension of one of the first or second major surfaces orthogonal to thethickness, and a length defined as a second dimension of one of thefirst or second major surfaces orthogonal to both the thickness and thewidth, and wherein the thickness is 1.5 mm or less, and wherein thesecond major surface comprises a first radius of curvature of 20 mm orgreater; and a display module attached to the second major surface andcomprising a second radius of curvature, wherein the first radius ofcurvature is within 10% of one of or both the radius of curvature of thecurved surface and the second radius of curvature.

Aspect (22) pertains to the vehicle interior system of Aspect (21),wherein the width is in a range from about 5 cm to about 250 cm, and thelength is from about 5 cm to about 250 cm.

Aspect (23) pertains to the vehicle interior system of Aspect (21) or(22), wherein the curved glass substrate is strengthened.

Aspect (24) pertains to the vehicle interior system of any one ofAspects (21) through (23), wherein the curved glass substrate iscold-bent.

Aspect (25) pertains to the vehicle interior system of any one ofAspects (21) through (24), further comprising an adhesive between theglass substrate and the display module.

Aspect (26) pertains to the vehicle interior system of Aspect (25),wherein the glass substrate comprises a periphery adjacent the minorsurface, and the adhesive is disposed between the periphery of thesecond major surface and the display module.

Aspect (27) pertains to the vehicle interior system of any one ofAspects (21) through (26), wherein the display module comprises a secondglass substrate and a backlight unit, wherein the second glass substrateis disposed adjacent the first major surface and between the backlightunit and the first major surface, and wherein the backlight unit isoptionally curved to exhibit the second radius of curvature.

Aspect (28) pertains to the vehicle interior system of Aspect (27),wherein the second glass substrate comprises a curved second glasssubstrate that is optionally cold-bent.

Aspect (29) pertains to the vehicle interior system of Aspect (27) or(28), wherein the display module further comprises a frame at leastpartially surrounding the backlight unit.

Aspect (30) pertains to the vehicle interior system of Aspect (29),wherein the frame at least partially surrounds the second glasssubstrate.

Aspect (31) pertains to the vehicle interior system of Aspect (29) or(30), wherein the frame at least partially surrounds the minor surfaceof the glass substrate.

Aspect (32) pertains to the vehicle interior system of Aspect (29) or(30), wherein the minor surface of the glass substrate is not surroundedby the frame.

Aspect (33) pertains to the vehicle interior system of Aspect (29),wherein the frame comprises an L-shape.

Aspect (34) pertains to the vehicle interior system of any one ofAspects (21) through (33), wherein either one of or both the first majorsurface and the second major surface comprises a surface treatment.

Aspect (35) pertains to the vehicle interior system of Aspect (34),wherein the surface treatment covers at least a portion of the firstmajor surface and the second major surface.

Aspect (36) pertains to the vehicle interior system of Aspect (34) or(35), wherein the surface treatment comprises any one of aneasy-to-clean surface, an anti-glare surface, an anti-reflectivesurface, a haptic surface, and a decorative surface.

Aspect (37) pertains to the vehicle interior system of Aspect (36),wherein the surface treatment comprises at least two of any one of aneasy-to-clean surface, an anti-glare surface, an anti-reflectivesurface, a haptic surface, and a decorative surface.

Aspect (38) pertains to the vehicle interior system of Aspect (37),wherein the first major surface comprises the anti-glare surface and thesecond major surface comprises the anti-reflective surface.

Aspect (39) pertains to the vehicle interior system of Aspect (37),wherein the first major surface comprises the anti-reflective surfaceand the second major surface comprises the anti-glare surface.

Aspect (40) pertains to the vehicle interior system of Aspect (37),wherein the first major surface comprises either one of or both theanti-glare surface and the anti-reflective surface, and the second majorsurface comprises the decorative surface.

Aspect (41) pertains to the vehicle interior system of Aspect (37),wherein the decorative surface is disposed on at least a portion of theperiphery and the interior portion is substantially free of thedecorative surface.

Aspect (42) pertains to the vehicle interior system of any one ofAspects (36) through (41), wherein the decorative surface comprises anyone of a wood-grain design, a brushed metal design, a graphic design, aportrait, and a logo.

Aspect (43) pertains to the vehicle interior system of any one ofAspects (36) through (42), wherein the anti-glare surface comprises anetched surface, and wherein the anti-reflective surface comprises amulti-layer coating.

Aspect (44) pertains to the vehicle interior system of any one ofAspects (21) through (43), further comprising touch functionality.

Aspect (45) pertains to the vehicle interior system of any one ofAspects (21) through (44), wherein the base comprises any one of acenter console, a dashboard, an arm rest, a pillar, a seat back, a floorboard, a headrest, a door panel, and a steering wheel.

Aspect (46) pertains to the vehicle interior system of any one ofAspects (21) through (45), wherein the vehicle is any one of anautomobile, a seacraft, and an aircraft.

Aspect (47) pertains to a method of forming a display comprising:cold-bending a glass substrate having a first major surface and a secondmajor surface opposite the first major surface to a first radius ofcurvature as measured on the second major surface; and laminating adisplay module to the first major surface while maintaining the firstradius of curvature in the glass substrate to form the display, whereinthe display module has a second radius of curvature that is within 10%of the first radius of curvature.

Aspect (48) pertains to the method of Aspect (47), wherein cold-bendingthe glass substrate comprises applying a vacuum to the second majorsurface to generate the first radius of curvature.

Aspect (49) pertains to the method of Aspect (48), wherein applying thevacuum comprises placing the glass substrate on a vacuum fixture beforeapplying the vacuum to the second major surface.

Aspect (50) pertains to the method of any one of Aspects (47) through(49), further comprising laminating an adhesive to the first majorsurface before laminating the display module to the first major surfacesuch that the adhesive is disposed between the first major surface andthe display module.

Aspect (51) pertains to the method of any one of Aspects (47) through(50), wherein laminating a display module comprises laminating a secondglass substrate to the glass substrate; and attaching a backlight unitto the second glass substrate, wherein the backlight unit is optionallycurved to exhibit the second radius of curvature.

Aspect (52) pertains to the method of Aspect (51), wherein laminatingthe second glass substrate comprises cold-bending the second glasssubstrate.

Aspect (53) pertains to the method of Aspect (51) or Aspect (52),further comprising attaching a frame with the backlight unit to thesecond glass substrate.

Aspect (54) pertains to the method of any one of Aspects (51) through(53), wherein the adhesive is disposed between the second glasssubstrate and the glass substrate.

Aspect (55) pertains to the method of any one of Aspects (48) through(54), further comprising removing the vacuum from the second majorsurface.

Aspect (56) pertains to the method of Aspect (55), wherein removing thevacuum from the second major surface comprises removing the display fromthe vacuum fixture.

Aspect (57) pertains to the method of any one of Aspects (47) through(56), wherein the glass substrate has a thickness of about 1.5 mm orless.

Aspect (58) pertains to the method of any one of Aspects (47) through(57), wherein the glass substrate is strengthened.

Aspect (59) pertains to the method of any one of Aspects (47) through(58), wherein the second glass substrate is unstrengthened.

Aspect (60) pertains to the method of any one of Aspects (51) through(59), wherein the second glass substrate has a thickness that is greaterthan a thickness of the glass substrate.

Aspect (61) pertains to the method of any one of Aspects (47) through(60), wherein the first radius of curvature is in a range from about 20mm to about 1500 mm.

Aspect (62) pertains to the method of any one of Aspects (50) through(61), wherein the adhesive has a thickness of about 1 mm or less.

Aspect (63) pertains to the method of any one of Aspects (47) through(62), further comprising disposing the display in a vehicle interiorsystem.

Aspect (64) pertains to a kit for providing a vehicle interior system,the kit comprising: a curved glass substrate that comprises a firstmajor surface, a second major surface opposing the first major surfaceand a minor surface connecting the first major surface and the secondmajor surface, a thickness defined as a distance between the first majorsurface and the second major surface, a width defined as a firstdimension of one of the first or second major surfaces orthogonal to thethickness, and a length defined as a second dimension of one of thefirst or second major surfaces orthogonal to both the thickness and thewidth, and wherein the thickness is 1.5 mm or less, and wherein thesecond major surface comprises a first radius of curvature; and a framehaving a curved surface having the first radius of curvature, whereinthe curved surface is coupled to the second major surface of the curvedglass substrate.

Aspect (65) pertains to the kit of Aspect (64), wherein the first radiusof curvature is 250 nm or greater and wherein the width is in a rangefrom about 5 cm to about 250 cm, and the length is from about 5 cm toabout 250 cm.

Aspect (66) pertains to the kit of Aspect (64) or (65), wherein thecurved glass substrate is cold-bent.

Aspect (67) pertains to the kit of any one of Aspects (64) through (66),further comprising a display module, a touch panel, or a display moduleand a touch panel.

Aspect (68) pertains to the kit of Aspect (67), wherein the displaymodule comprises a display and a back-light unit.

Aspect (69) pertains to the kit of Aspect (68), wherein the display is aliquid crystal display or an organic light-emitting diode display.

Aspect (70) pertains to the kit of Aspect (68) or Aspect (69), whereinthe display comprises a second glass substrate that is curved.

Aspect (71) pertains to the kit of Aspect (65), wherein the touch panelcomprises a second glass substrate that is curved.

Aspect (72) pertains to the kit of Aspect (70) or Aspect (71), whereinthe second glass substrate comprises a display surface having a secondradius of curvature that is within 10% of the first radius of curvature.

Aspect (73) pertains to the kit of any one of Aspects (70) through (72),wherein the second glass substrate comprises an adhesive layer forattachment to the curved glass substrate or the frame.

Aspect (74) pertains to the kit of any one of Aspects (70) through (73),wherein the second glass substrate is attached to the first majorsurface or the frame, and the backlight unit is configured forattachment to the second glass substrate such that the second glasssubstrate is between the curved glass substrate and the backlight unit.

Aspect (75) pertains to the kit of any one of Aspects (68) through (69),wherein the display comprises a second glass substrate that issubstantially flat and is cold-bendable to a second radius of curvaturethat is within 10% of the first radius of curvature.

Aspect (76) pertains to the kit of Aspect (67), wherein the touch panelcomprises a second glass substrate that is substantially flat and iscold-bendable to a second radius of curvature that is within 10% of thefirst radius of curvature.

Aspect (77) pertains to the kit of Aspect (75) or (76), wherein thesecond glass substrate comprises an adhesive layer for attachment to thecold-bent glass substrate or the frame.

Aspect (78) pertains to the kit of any one of Aspects (75) through (77),wherein the second glass substrate is cold-bent to the second radius ofcurvature and attached to the cold-bent glass substrate or the frame.

Aspect (79) pertains to the kit of any one of Aspects (68) through (69),Aspects (71) through (75) and Aspects (77) through (78), wherein thebacklight unit is curved and exhibits a third radius of curvature thatis within 10% of the first radius of curvature.

Aspect (80) pertains to the kit of any one of Aspects (71) through (79),wherein the backlight unit is curved and exhibits a third radius ofcurvature that is within 10% of the second radius of curvature.

Aspect (81) pertains to the kit of any one of Aspects (71) through (80),wherein the backlight unit is curved and exhibits a third radius ofcurvature that is within 10% of the first radius of curvature and thesecond radius of curvature.

Aspect (82) pertains to the kit of Aspect (68) or (69), wherein thedisplay comprises a second glass substrate that is substantially flatand is attached to the first major surface, and the backlight unit isconfigured for attachment to the second glass substrate such that thesecond glass substrate is between the curved glass substrate and thebacklight unit.

Aspect (83) pertains to the kit of Aspect (67), wherein the touch panelcomprises a second glass substrate that is substantially flat and isattached to the first major surface.

Aspect (84) pertains to the kit of Aspect (82) or (83), wherein thesecond glass substrate comprises an adhesive layer that attaches thesecond glass substrate to the first major surface, wherein the adhesivelayer comprises a first surface that is substantially flat and anopposing second surface having a second radius of curvature that iswithin the 10% of the first radius of curvature.

Aspect (85) pertains to the kit of any one of Aspects (74), and (78)through (84), further comprising an air gap disposed between the secondglass substrate and the first major surface.

Aspect (86) pertains to a kit for providing a vehicle interior system,the kit comprising: a curved glass substrate that comprises a firstmajor surface, a second major surface opposing the first major surfaceand a minor surface connecting the first major surface and the secondmajor surface, a thickness defined as a distance between the first majorsurface and the second major surface, a width defined as a firstdimension of one of the first or second major surfaces orthogonal to thethickness, and a length defined as a second dimension of one of thefirst or second major surfaces orthogonal to both the thickness and thewidth, and wherein the thickness is 1.5 mm or less, and wherein thesecond major surface comprises a first radius of curvature; and aremovable frame having a curved surface having the first radius ofcurvature, wherein the curved surface is removably coupled to the secondmajor surface of the curved glass substrate.

Aspect (87) pertains to the kit of Aspect (86), wherein the first radiusof curvature is 250 nm or greater and wherein the width is in a rangefrom about 5 cm to about 250 cm, and the length is from about 5 cm toabout 250 cm.

Aspect (88) pertains to the kit of Aspect (86) or (87), wherein thecurved glass substrate is cold-bent.

Aspect (89) pertains to the kit of any one of Aspects (86) through (88),further comprising a display module, a touch panel, or a display moduleand a touch panel.

Aspect (90) pertains to the kit of Aspect (89), wherein the displaymodule comprises a display and a backlight unit.

Aspect (91) pertains to the kit of Aspect (90), wherein the display is aliquid crystal display or an organic light-emitting diode display.

Aspect (92) pertains to the kit of Aspect (90) or (91), wherein thedisplay comprises a second glass substrate that is curved.

Aspect (93) pertains to the kit of Aspect (89), wherein the touch panelcomprises a second glass substrate that is curved.

Aspect (94) pertains to the kit of Aspect (92) or (93), wherein thesecond glass substrate comprises a display surface having a secondradius of curvature that is within 10% of the first radius of curvature.

Aspect (95) pertains to the kit of any one of Aspects (92) through (94),wherein the second glass substrate comprises an adhesive layer forattachment to the curved glass substrate.

Aspect (96) pertains to the kit of any one of Aspects (90) through (95),wherein the second glass substrate is attached to the first majorsurface, and the backlight unit is configured for attachment to thesecond glass substrate such that the second glass substrate is betweenthe curved glass substrate and the backlight unit.

Aspect (97) pertains to the kit of Aspect (90) or (91), wherein thedisplay comprises a second glass substrate that is substantially flatand is cold-bendable to a second radius of curvature that is within 10%of the first radius of curvature.

Aspect (98) pertains to the kit of Aspect (89), wherein the touch panelcomprises a second glass substrate that is substantially flat and iscold-bendable to a second radius of curvature that is within 10% of thefirst radius of curvature.

Aspect (99) pertains to the kit of Aspect (97) or (98), wherein thesecond glass substrate comprises an adhesive layer for attachment to thecurved glass substrate.

Aspect (100) pertains to the kit of any one of Aspects (97) through(99), wherein the second glass substrate is cold-bent to the secondradius of curvature and attached to the curved glass substrate, and thebacklight unit is configured for attachment to the second glasssubstrate such that the second glass substrate is between the curvedglass substrate and the backlight unit.

Aspect (101) pertains to the kit of any one of Aspects (90) through(92), Aspects (94) through (97), and Aspects (99) through (100), whereinthe backlight unit is curved and exhibits a third radius of curvaturethat is within 10% of the first radius of curvature.

Aspect (102) pertains to the kit of any one of Aspects (97) through(101), wherein the backlight unit is curved and exhibits a third radiusof curvature that is within 10% of the second radius of curvature.

Aspect (103) pertains to the kit of any one of Aspects (97) through(102), wherein the backlight unit is curved and exhibits a third radiusof curvature that is within 10% of the first radius of curvature and thesecond radius of curvature.

Aspect (104) pertains to the kit of Aspect (90) or (91), wherein thedisplay comprises a second glass substrate that is substantially flatand is attached to the first major surface, and the backlight unit isconfigured for attachment to the second glass substrate such that thesecond glass substrate is between the curved glass substrate and thebacklight unit.

Aspect (105) pertains to the kit of Aspect (89), wherein the touch panelcomprises a second glass substrate that is substantially flat and isattached to the first major surface.

Aspect (106) pertains to the kit of Aspect (104) or (105), wherein thesecond glass substrate comprises an adhesive layer that attaches thesecond glass substrate to the first major surface.

Aspect (107) pertains to the kit of Aspect (106), wherein the adhesivelayer comprises a first surface have in that is substantially flat andan opposing second surface having a second radius of curvature that iswithin the 10% of the first radius of curvature.

Aspect (108) pertains to the kit of any one of Aspect (96) and Aspects(100) through (107), further comprising an air gap disposed between thesecond glass substrate and the first major surface.

Aspect (109) pertains to a kit for providing a vehicle interior system,the kit comprising: a flexible glass substrate that comprises a firstmajor surface, a second major surface opposing the first major surfaceand a minor surface connecting the first major surface and the secondmajor surface, a thickness defined as a distance between the first majorsurface and the second major surface, a width defined as a firstdimension of one of the first or second major surfaces orthogonal to thethickness, and a length defined as a second dimension of one of thefirst or second major surfaces orthogonal to both the thickness and thewidth, and wherein the thickness is 1.5 mm or less; and a curved displaymodule or curved touch panel having a first radius of curvature.

Aspect (110) pertains to the kit of Aspect (109), wherein the firstradius of curvature is 500 nm or greater.

Aspect (111) pertains to the kit of Aspect (109) or (110), wherein thewidth is in a range from about 5 cm to about 250 cm, and the length isfrom about 5 cm to about 250 cm.

Aspect (112) pertains to the kit of any one of Aspects (109) through(111), wherein the display module comprises a display and a backlightunit.

Aspect (113) pertains to the kit of Aspect (112), wherein the display isa liquid crystal display or an organic light-emitting diode display.

Aspect (114) pertains to the kit of any one of Aspects (112) through(113), wherein the display module comprises a second glass substratewith a second glass surface, the second glass surface comprises thefirst radius of curvature.

Aspect (115) pertains to the kit of any one of Aspects (109) through(111), wherein the touch panel comprises a second glass substrate with asecond glass surface, the second glass surface comprises the firstradius of curvature.

Aspect (116) pertains to the kit of Aspect (114) or (115), wherein theflexible glass substrate is cold-bent and the second major surface ofthe flexible glass substrate comprises a second radius of curvature thatis within 10% of the first radius of curvature.

Aspect (117) pertains to the kit of any one of Aspects (114) through(116), wherein either one of or both the first major surface and thesecond glass surface comprises an adhesive layer for attachment of theflexible glass substrate and the second glass substrate.

Aspect (118) pertains to the kit of any one of Aspects (114) through(117), wherein the second glass substrate is attached to the first majorsurface, and the backlight unit is configured for attachment to thesecond glass substrate such that the second glass substrate is betweenthe curved glass substrate and the backlight unit.

Aspect (119) pertains to the kit of any one of Aspects (112) through(114) and Aspects (116) through (118), wherein the backlight unit iscurved and exhibits a third radius of curvature that is within 10% ofthe first radius of curvature.

Aspect (120) pertains to the kit of any one of Aspects (116) through(119), wherein the backlight unit is curved and exhibits a third radiusof curvature that is within 10% of the second radius of curvature.

Aspect (121) pertains to the kit of any one of Aspects (116) through(120), wherein the backlight unit is curved and exhibits a third radiusof curvature that is within 10% of the first radius of curvature and thesecond radius of curvature.

Aspect (122) pertains to the kit of any one of Aspects (118) through(121), further comprising an air gap disposed between the second glasssubstrate and the first major surface.

Aspect (123) pertains to a method of forming a display comprising:cold-bending a stack to a first radius of curvature as measured on afirst surface, the stack comprising a first glass substrate having afirst major surface forming the first surface of the stack and a secondmajor surface opposite the first major surface, a display module ortouch panel comprising a second glass substrate disposed on the secondmajor surface, wherein the second glass substrate is adjacent the secondmajor surface; and laminating the display module or touch panel to thesecond major surface such that second glass substrate comprises a secondradius of curvature that is within 10% of the first radius of curvature.

Aspect (124) pertains to the method of Aspect (123), whereincold-bending the stack comprises applying a vacuum to the first surfaceto generate the first radius of curvature.

Aspect (125) pertains to the method of Aspect (124), wherein applyingthe vacuum comprises placing the stack on a vacuum fixture beforeapplying the vacuum to the first surface.

Aspect (126) pertains to the method of any one of Aspects (123) through(125), further comprising applying an adhesive layer between the secondglass substrate and the first glass substrate before cold-bending thestack.

Aspect (127) pertains to the method of Aspect (126), wherein theadhesive layer is disposed on a portion of the second glass substrate orthe first glass substrate.

Aspect (128) pertains to the method of any one of Aspects (123) through(127), wherein the display module comprises a cold-bendable backlightunit disposed on the second glass substrate opposite the first glasssubstrate.

Aspect (129) pertains to the method of any one of Aspects (123) through(127), wherein laminating a display module comprises attaching abacklight unit to the second glass substrate opposite the first glasssubstrate, wherein the backlight unit is optionally curved to exhibitthe second radius of curvature.

Aspect (130) pertains to the method of any one of Aspects (123) through(128), further comprising attaching a frame to the first glass substrateto maintain the first radius of curvature.

Aspect (131) pertains to the method of any one of Aspects (123) through(130), wherein the first glass substrate has a thickness of about 1.5 mmor less.

Aspect (132) pertains to the method of any one of Aspects (123) through(131), wherein the first glass substrate is strengthened.

Aspect (133) pertains to the method of any one of Aspects (123) through(132), wherein the second glass substrate is unstrengthened.

Aspect (134) pertains to the method of any one of Aspects (123) through(133), wherein the second glass substrate has a thickness that isgreater than a thickness of the glass substrate.

Aspect (135) pertains to the method of any one of Aspects (123) through(134), wherein the first radius of curvature is in a range from about 20mm to about 1500 mm.

Aspect (136) pertains to the method of any one of Aspects (123) through(135), further comprising disposing the display in a vehicle interiorsystem.

It will be apparent to those skilled in the art that variousmodifications and variations can be made without departing from thespirit or scope of the invention.

What is claimed is:
 1. A vehicle interior system comprising a basehaving a curved surface; a display disposed on the curved surface, thedisplay comprising a curved and cold-bent glass substrate comprising afirst major surface, a second major surface opposing the first majorsurface and a minor surface connecting the first major surface and thesecond major surface, a thickness defined as a distance between thefirst major surface and the second major surface, a width defined as afirst dimension of one of the first or second major surfaces orthogonalto the thickness, and a length defined as a second dimension of one ofthe first or second major surfaces orthogonal to both the thickness andthe width, and wherein the thickness is 1.5 mm or less, the width is ina range from about 5 cm to about 250 cm, and the length is from about 5cm to about 250 cm, and wherein the second major surface comprises afirst radius of curvature of 20 mm or greater; and a display moduleattached to the second major surface and comprising a second radius ofcurvature, wherein the first radius of curvature is within 10% of one ofor both the radius of curvature of the curved surface and the secondradius of curvature.
 2. The vehicle interior system of claim 1, whereinthe curved glass substrate is strengthened.
 3. The vehicle interiorsystem of claim 1, further comprising an adhesive between the glasssubstrate and the display module.
 4. The vehicle interior system ofclaim 1, wherein the display module comprises a second glass substrateand a backlight unit, wherein the second glass substrate is disposedadjacent the first major surface and between the backlight unit and thefirst major surface, and wherein the backlight unit is optionally curvedto exhibit the second radius of curvature.
 5. The vehicle interiorsystem of claim 4, wherein the second glass substrate comprises a curvedsecond glass substrate that is cold-bent.
 6. The vehicle interior systemof claim 4, wherein the display module further comprises a frame atleast partially surrounding the backlight unit, at least partiallysurrounds the second glass substrate, or at least partially surroundsthe minor surface of the glass substrate.
 7. The vehicle interior systemof claim 6, wherein the minor surface of the glass substrate is notsurrounded by the frame.
 8. The vehicle interior system of claim 6,wherein the frame comprises an L-shape.
 9. The vehicle interior systemof claim 1, wherein either one of or both the first major surface andthe second major surface comprises a surface treatment wherein thesurface treatment comprises any one of an easy-to-clean surface, ananti-glare surface, an anti-reflective surface, a haptic surface, and adecorative surface.
 10. The vehicle interior system of claim 1, furthercomprising touch functionality.
 11. The vehicle interior system of claim1, wherein the base comprises any one of a center console, a dashboard,an arm rest, a pillar, a seat back, a floor board, a headrest, a doorpanel, and a steering wheel.
 12. The vehicle interior system of claim 1,wherein the vehicle is any one of an automobile, a seacraft, and anaircraft.
 13. A vehicle interior system comprising a base having acurved surface; a display disposed on the curved surface, the displaycomprising a curved and cold-bent glass substrate comprising a firstmajor surface, a second major surface opposing the first major surface,and a minor surface connecting the first major surface and the secondmajor surface, a thickness defined as a distance between the first majorsurface and the second major surface, a width defined as a firstdimension of one of the first or second major surfaces orthogonal to thethickness, and a length defined as a second dimension of one of thefirst or second major surfaces orthogonal to both the thickness and thewidth, and wherein the thickness is 1.5 mm or less, and wherein thesecond major surface comprises a first radius of curvature of 20 mm orgreater; a display module attached to the second major surface andcomprising a second radius of curvature; and an adhesive between theglass substrate and the display module, wherein the glass substratecomprises a periphery adjacent the minor surface, and the adhesive isdisposed between the periphery of the second major surface and thedisplay module, wherein the first radius of curvature is within 10% ofone of or both the radius of curvature of the curved surface and thesecond radius of curvature.
 14. The vehicle interior system of claim 13,wherein the width is in a range from about 5 cm to about 250 cm, and thelength is from about 5 cm to about 250 cm.
 15. The vehicle interiorsystem of claim 13, wherein the curved glass substrate is strengthened.16. The vehicle interior system of claim 13, wherein either one of orboth the first major surface and the second major surface comprises asurface treatment wherein the surface treatment comprises any one of aneasy-to-clean surface, an anti-glare surface, an anti-reflectivesurface, a haptic surface, and a decorative surface.
 17. The vehicleinterior system of claim 13, further comprising touch functionality. 18.The vehicle interior system of claim 13, wherein the base comprises anyone of a center console, a dashboard, an arm rest, a pillar, a seatback, a floor board, a headrest, a door panel, and a steering wheel. 19.A vehicle interior system comprising a base having a curved surface; adisplay disposed on the curved surface, the display comprising a curvedand cold-bent glass substrate comprising a first major surface, a secondmajor surface opposing the first major surface and a minor surfaceconnecting the first major surface and the second major surface, athickness defined as a distance between the first major surface and thesecond major surface, a width defined as a first dimension of one of thefirst or second major surfaces orthogonal to the thickness, and a lengthdefined as a second dimension of one of the first or second majorsurfaces orthogonal to both the thickness and the width, and wherein thethickness is 1.5 mm or less, and wherein the second major surfacecomprises a first radius of curvature of 20 mm or greater; and a displaymodule attached to the second major surface and comprising a secondradius of curvature and a second glass substrate and a backlight unit,wherein the second glass substrate is disposed adjacent the first majorsurface and between the backlight unit and the first major surface, andwherein the backlight unit is optionally curved to exhibit the secondradius of curvature, wherein the first radius of curvature is within 10%of one of or both the radius of curvature of the curved surface and thesecond radius of curvature.
 20. The vehicle interior system of claim 19,wherein the width is in a range from about 5 cm to about 250 cm, and thelength is from about 5 cm to about 250 cm.
 21. The vehicle interiorsystem of claim 19, wherein the curved glass substrate is strengthened.22. The vehicle interior system of claim 19, wherein the display modulefurther comprises a frame at least partially surrounding the backlightunit, at least partially surrounds the second glass substrate, or atleast partially surrounds the minor surface of the glass substrate. 23.The vehicle interior system of claim 19, wherein either one of or boththe first major surface and the second major surface comprises a surfacetreatment wherein the surface treatment comprises any one of aneasy-to-clean surface, an anti-glare surface, an anti-reflectivesurface, a haptic surface, and a decorative surface.
 24. The vehicleinterior system of claim 19, further comprising touch functionality. 25.The vehicle interior system of claim 19, wherein the base comprises anyone of a center console, a dashboard, an arm rest, a pillar, a seatback, a floor board, a headrest, a door panel, and a steering wheel. 26.A vehicle interior system comprising a base having a curved surface; adisplay disposed on the curved surface, the display comprising a curvedand cold-bent glass substrate comprising a first major surface, a secondmajor surface opposing the first major surface and a minor surfaceconnecting the first major surface and the second major surface, athickness defined as a distance between the first major surface and thesecond major surface, a width defined as a first dimension of one of thefirst or second major surfaces orthogonal to the thickness, and a lengthdefined as a second dimension of one of the first or second majorsurfaces orthogonal to both the thickness and the width, and wherein thethickness is 1.5 mm or less, and wherein the second major surfacecomprises a first radius of curvature of 20 mm or greater; and a displaymodule attached to the second major surface and comprising a secondradius of curvature, wherein the first radius of curvature is within 10%of one of or both the radius of curvature of the curved surface and thesecond radius of curvature, and wherein either one of or both the firstmajor surface and the second major surface comprises a surface treatmentwherein the surface treatment comprises any one of an easy-to-cleansurface, an anti-glare surface, an anti-reflective surface, a hapticsurface, and a decorative surface.
 27. The vehicle interior system ofclaim 26, the width is in a range from about 5 cm to about 250 cm, andthe length is from about 5 cm to about 250 cm.
 28. The vehicle interiorsystem of claim 26, wherein the curved glass substrate is strengthened.29. The vehicle interior system of claim 26, further comprising touchfunctionality.
 30. The vehicle interior system of claim 26, wherein thebase comprises any one of a center console, a dashboard, an arm rest, apillar, a seat back, a floor board, a headrest, a door panel, and asteering wheel.